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Home › Ford › 2006 › Focus ZX4 ST › Repair and Diagnosis › Transmission › Manual Trans › Manual Transmission › Disassembly And Assembly Of Subassemblies › Output Shaft › Disassembly

Output Shaft: Disassembly

CAUTION: The inner synchronizer ring and the synchronizer cone must be handled very carefully.
    CAUTION: Only loosely attach the special tool to avoid damaging the synchronizer ring.
    Fig 1: Removing Output Shaft Bearing And Reverse Gear
    G04653432Courtesy of FORD MOTOR CO.
  1. Using a press and the special tool, remove the output shaft bearing and the reverse gear. Discard the output shaft bearing.
  2. Remove the reverse gear needle bearing and the synchronizer ring.
    Fig 2: Locating Reverse Gear Needle Bearing And Synchronizer Ring
    G04653433Courtesy of FORD MOTOR CO.
  3. Remove the 5th/reverse gear synchronizer assembly.
    • Remove and discard the snap ring, and remove the synchronizer assembly.
      Fig 3: Identifying Snap Ring, And Remove Synchronizer Assembly
      G04653434Courtesy of FORD MOTOR CO.
  4. Remove the synchronizer ring, 5th gear and 5th gear needle bearing.
    Fig 4: Locating Synchronizer Ring, 5th Gear And 5th Gear Needle Bearing
    G04653435Courtesy of FORD MOTOR CO.
    5. NOTE: Position the special tool with the flat side upward.
    Fig 5: Removing Snap Ring
    G04653436Courtesy of FORD MOTOR CO.
  5. Using the special tool, remove and discard the snap ring, then remove the 4th gear.
    6. NOTE: Position the special tool with the fiat side upward.
    Fig 6: Removing 2nd And 3rd Gear
    G04653437Courtesy of FORD MOTOR CO.
  6. Using the special tool, remove the 2nd and the 3rd gear.
    7. CAUTION: Be extremely careful when handling the inner synchronizer ring and synchronizer cone.
  7. Remove the following:
    1. The outer synchronizer ring.
    2. The synchronizer cone.
    3. The inner synchronizer ring.
    4. Second gear.
    5. Second gear needle bearing.
      Fig 7: Identifying Second Gear Needle Bearing
      G04653438Courtesy of FORD MOTOR CO.
  8. Remove and discard the snap ring, then remove the 1st/2nd gear synchronizer hub assembly.
    Fig 8: Locating 1st/2nd Gear Synchronizer Hub Assembly
    G04653439Courtesy of FORD MOTOR CO.
    9. CAUTION: Be extremely careful when handling the inner synchronizer ring and synchronizer cone.
  9. Remove the following:
    1. The outer synchronizer ring.
    2. The inner synchronizer ring.
    3. The synchronizer cone.
    4. First gear.
    5. First gear needle bearing.
      Fig 9: Identifying Inner Synchronizer Ring And Synchronizer Cone
      G04653440Courtesy of FORD MOTOR CO.
  10. Using the special tool, remove the clutch housing roller bearing.
    Fig 10: Removing Clutch Housing Roller Bearing
    G04653441Courtesy of FORD MOTOR CO.
    11. NOTE: Mark the installed position of the selector ring.
  11. Disassemble the 1st/2nd and 5th/reverse synchronizer hub assemblies. Remove the selector ring from the synchronizer hub. Remove the compression springs, the keys and the detent balls.
    • Take care when pulling the selector ring from the synchronizer hub. The detent balls are spring-loaded.
      Fig 11: Locating Selector Ring From Synchronizer Hub
      G04653442Courtesy of FORD MOTOR CO.
  12. Inspect the synchronizer assemblies.
    • Check for worn, nicked or broken teeth. Install a new synchronizer as necessary.
    • Check keys for wear or distortion. Install a new synchronizer as necessary.
    • Check springs for distortion. Install a new synchronizer as necessary.
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