Output Shaft: Assembly

NOTE: Do not lubricate new roller bearings.

Lubricate all transmission components with transmission fluid during reassembly.

CAUTION: Handle the inner synchronizer ring and synchronizer cone very carefully.

Install the following:
1. The 1st gear needle bearing.
2. First gear.
3. The inner synchronizer ring.
4. The synchronizer cone.
5. The outer synchronizer ring.
  
  Fig 1: Identifying Inner And Outer Synchronizer Ring And Cone
  Courtesy of FORD MOTOR CO.

NOTE: Observe the markings on the selector ring.

NOTE: Place a rubber band around the synchronizer body. Install the springs, the synchronizer bars and detent balls. Slide the synchronizer sleeve over the synchronizer body, while moving the rubber band downward.

Assemble the synchronizer hub assembly.
1. Install the compression springs.
2. Install the keys and the detent balls in the gear synchronizer hub against the force of the spring.
3. Align the selector ring with the hub and push it on.
  
  Fig 2: Identifying Compression Springs And Selector Ring
  Courtesy of FORD MOTOR CO.

NOTE: Install the synchronizer hub assembly with the larger collar facing toward 2nd gear.

Fig 3: Locating 1st/2nd Gear Synchronizer Hub And Snap Ring

Courtesy of FORD MOTOR CO.

Install the 1st/2nd gear synchronizer hub assembly, then install a new snap ring.
Install the following:
1. The 2nd gear needle bearing.
2. The outer synchronizer ring.
3. The synchronizer cone.
4. The inner synchronizer ring.
5. Second gear.
  
  Fig 4: Identifying 2nd Gear Needle Bearing And Cone
  Courtesy of FORD MOTOR CO.
Using a press and the special tool, install 3rd gear.

Fig 5: Installing 3rd Gear
Courtesy of FORD MOTOR CO.
Using a press and the special tool, install 4th gear. Install a new snap ring.

Fig 6: Installing 4th Gear And Snap Ring
Courtesy of FORD MOTOR CO.
Install the 5th gear needle bearing, 5th gear and the synchronizer ring.

Fig 7: Installing 5th Gear Needle Bearing, 5th Gear And Synchronizer Ring
Courtesy of FORD MOTOR CO.

NOTE: Install the synchronizer hub assembly with the small collar and the ring groove facing outward.

Fig 8: Installing Fifth/Reverse Gear Synchronizer Assembly

Courtesy of FORD MOTOR CO.

Install the 5th/reverse gear synchronizer assembly. Install a new snap ring.
Install the synchronizer ring, the reverse gear needle bearing and the reverse gear.

Fig 9: Locating Synchronizer Ring, Reverse Gear Needle Bearing And Reverse Gear
Courtesy of FORD MOTOR CO.
Using a press, install a new output shaft bearing.
- Press the bearing on the inner race only. Use a suitable step plate to install.
  
  Fig 10: Installing Output Shaft Bearing
  Courtesy of FORD MOTOR CO.
Using a press, install a new output shaft bearing.
- Press the bearing on the inner race only. Use a suitable step plate to install.
  
  Fig 11: Installing Output Shaft Bearing
  Courtesy of FORD MOTOR CO.