Output Shaft

Output Shaft

WARNING: Before beginning any service procedure, REFER to Safety Warnings . Failure to follow this instruction may result in serious personal injury.

Special Tool(s)






Material(s)






Exploded View










Disassembly

NOTE: The inner synchronizer ring and the synchronizer cone must be handled very carefully.

1. NOTICE: Only loosely attach the Bearing/Gear Remover to avoid damaging the synchronizer ring.

Using a press and 205-D064 (D84L-1123-A) , 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.





3. Remove and discard the snap ring and the 5th/reverse gear synchronizer assembly.





4. Remove the synchronizer ring, 5th gear and 5th gear needle bearing.

- Check all components for wear or damage. Install new components as necessary.






5. NOTE: Position 205-D064 (D84L-1123-A) with the flat side upward.
Using 205-D064 (D84L-1123-A) , remove and discard the snap ring, then remove the 4th gear.

- Check 4th gear for wear or damage. Install a new gear as necessary.






6. NOTE: Position 205-D064 (D84L-1123-A) with the flat side upward.
Using 205-D064 (D84L-1123-A) , remove the 2nd and the 3rd gear.

- Check 2nd and 3rd gear for wear or damage. Install new gears as necessary.






7. Remove the following:

1. Outer synchronizer ring

2. Synchronizer cone

3. Inner synchronizer ring

4. Second gear

5. Second gear needle bearing

- Check all components for wear or damage. Install new components as necessary






8. Remove and discard the snap ring, then remove the 1st/2nd gear synchronizer hub assembly.

- Check the synchronizer for wear or damage. Install a new synchronizer as necessary.






9. Remove the following:

1. Outer synchronizer ring

2. Inner synchronizer ring

3. Synchronizer cone

4. First gear

5. First gear needle bearing

- Check all components for wear or damage. Install new components as necessary






10. Using 205-D064 (D84L-1123-A) , remove the clutch housing roller bearing.





11. NOTE: Mark the installed position of the selector ring.
Disassemble the 1st/2nd and 5th/reverse synchronizer hub assemblies. Take care when pulling the selector ring from the synchronizer hub. The detent balls are spring-loaded. Remove the selector ring from the synchronizer hub. Remove the compression springs, the keys and the detent balls.





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.

Assembly

1. NOTE: Do not lubricate new roller bearings.
Lubricate all other transmission components with Motorcraft(R) Full Synthetic Manual Transmission Fluid during reassembly.

2. NOTE: Handle the inner synchronizer ring and synchronizer cone very carefully.
Install the following:

1. First gear needle bearing

2. First gear

3. Inner synchronizer ring

4. Synchronizer cone

5. Outer synchronizer ring






3. 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.






4. NOTE: Install the synchronizer hub assembly with the larger collar facing toward 2nd gear.
Install the 1st/2nd gear synchronizer hub assembly, then install a new snap ring.





5. Install the following:

1. Second gear needle bearing

2. Outer synchronizer ring

3. Synchronizer cone

4. Inner synchronizer ring

5. Second gear






6. Using a press and 308-052 (T77J-7025-B) , install 3rd gear.





7. Using a press and 308-052 (T77J-7025-B) , install 4th gear. Install a new snap ring.





8. Install the 5th gear needle bearing, 5th gear and the synchronizer ring.





9. NOTE: Install the synchronizer hub assembly with the small collar and the ring groove facing outward.
Install the 5th/reverse gear synchronizer assembly and a new snap ring.





10. Install the synchronizer ring, the reverse gear needle bearing and the reverse gear.





11. Using 205-D015 (D80L-630-4) and a press, press the bearing on by the inner race only. Install a new output shaft bearing.





12. Using 205-D015 (D80L-630-4) and a press, press the bearing on by the inner race only. Install a new output shaft bearing.