Output Shaft: Disassembly

NOTE: When pressing off components, hold the shaft so it does not fall.

Measure the output shaft clearances.
1. Measure the clearance between 1st gear and the differential drive gear. First gear endplay is 0.05-0.33 mm (0.001-0.012 in).
2. Measure the clearance between 2nd gear and secondary 3rd gear. Second gear endplay is 0.18-0.51 mm (0.007-0.02 in).
  
  Fig 1: Identifying Differential Drive Gear And Secondary Gear
  Courtesy of FORD MOTOR CO.
Using the Bearing Puller and a suitable press, press off the bearing and 4th gear.
- Discard the bearing.
- Always install new bearings and cups as a set.
  
  Fig 2: Pressing Off Bearing And 4th Gear Using Bearing Puller And Suitable Press (205-D064)
  Courtesy of FORD MOTOR CO.
Remove and discard the snap ring.

Fig 3: Locating Snap Ring
Courtesy of FORD MOTOR CO.
Using the Bearing Puller and a suitable press, press off the 3rd gear and 2nd gear.

Fig 4: Pressing Off 2nd Gear And 3rd Gear Using Bearing Puller And Suitable Press (205-D064)
Courtesy of FORD MOTOR CO.

NOTE: The synchronizer blocking rings are not interchangeable. Be sure to keep them in the order that they were removed.

Fig 5: Locating Synchronizer Blocking Ring

Courtesy of FORD MOTOR CO.

Remove the synchronizer blocking ring, the synchronizer inner cone and the synchronizer outer cone.
Remove and discard the snap ring.

Fig 6: Locating Snap Ring
Courtesy of FORD MOTOR CO.

NOTE: The synchronizer blocking rings are not interchangeable. Make sure to keep them in the order that they were removed.

Fig 7: Pressing Off Synchronizer Hub, Synchronizer Blocking Ring And 1St Gear Using Bearing/Oil Seal Plate And Suitable Press

Courtesy of FORD MOTOR CO.

Using the Bearing/Oil Seal Plate and a suitable press, press off the synchronizer hub, synchronizer blocking ring and 1st gear.

NOTE: Using a paint pen, mark the hub to sleeve position for reassembly.

NOTE: Always install new bearings and cups as a set.

Fig 9: Pressing Off Bearing Using Bearing Puller And Suitable Press (205-D064)

Courtesy of FORD MOTOR CO.

Using the Bearing Puller and a suitable press, press off the bearing and discard.
Using a Dial Indicator Gauge with Holding Fixture, measure the output shaft gear runout.
- Inspect the output shaft for wear or damage.
- Inspect the output shaft for a plugged oil passage.
- Maximum output shaft gear runout is 0.015 mm (0.0006 in).
- Install a new output shaft as necessary.
  
  Fig 10: Measuring Output Shaft Gear Runout Using Dial Indicator Gauge (100-002)
  Courtesy of FORD MOTOR CO.
Set the synchronizer ring squarely in the gear, then measure around the circumference.
- Measure the clearance from the side of the gear.
  - Synchronizer ring clearance is 0.80-1.50 mm (0.031-0.059 in).
- Inspect for smooth engagement with the gear.
- Inspect for worn or damaged teeth or tapered surface. Install new components as necessary.
  
  Fig 11: Measuring Clearance From Side Of Gear
  Courtesy of FORD MOTOR CO.
Inspect the synchronizer hub.
- Inspect for worn or damaged splines, synchronizer insert groove or end surface.
- Inspect for smooth hub sleeve movement when it is installed.
Measure the clearance between the 1st/2nd synchronizer hub and its shift fork.
- Shift fork and hub sleeve clearance is 0.10-0.95 mm (0.003-0.037 in).