Output Shaft: Service and Repair

DISASSEMBLY





1. Press the bearing using Bearing Pulling Attachment.

CAUTION: The bearing is damaged when it is pressed off using the separating tool and cannot be re-used.





2. Remove the reverse gear.
1 Remove the reverse gear.
2 Remove the bearing.
3 Remove the synchronizer ring.





3. Remove the fifth/reverse gear synchronizer assembly.
1 Remove the snap-ring.
2 Remove the synchronizer assembly.





4. Remove fifth gear synchronizer ring bearing.
1 Remove the synchronizer ring.
2 Remove the fifth gear.
3 Remove the bearing.





5. Remove the bearing using Bearing Puller Attachment.

CAUTION: The bearing is damaged when it is pressed off using the separating tool and cannot be re-used.





6. Remove the output pinion and first gear.
1 Remove the snap-ring.
2 Remove the output pinion and first gear together.

CAUTION:
- Note the marks on the output pinion for reinstallation. The output shaft and output pinion belong together and can only be replaced as a pair.
- Only loosely attach the separating tool to avoid damaging the synchronizer ring.





7. Remove the bearing and first gear synchronizer ring.





8. Remove the first/second gear synchronizer assembly.
1 Remove the snap-ring.
2 Remove the synchronizer assembly.





9. Remove the synchronizer ring, second gear, and needle roller bearing from the output shaft.
1 Remove the second gear synchronizer ring.
2 Remove second gear.
3 Remove the needle roller bearing.

ASSEMBLY

CAUTION: Immerse the double synchronizer units in a bath of Motorcraft MERCON Multi-purpose Automatic Transmission Fluid XT-2-QDX or equivalent meeting MERCON specification before installation. MERCON(R) automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid, as per TSB 06-14-4.

1. Carefully clean and check all sliding parts and lubricate them with Motorcraft MERCON Multi-purpose Automatic Transmission Fluid XT-2-QDX or equivalent meeting MERCON specification before installation. MERCON(R) automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid, as per TSB 06-14-4.





Install the second gear wheel with the synchronizer and needle roller bearing.
1 Install the needle roller bearing.
2 Install the second gear.
3 Install the second gear synchronizer ring.





2. Installation position of the synchronizer assembly.

NOTE: Install the synchronizer ring hub with the small collar and the annular groove of the selector ring facing outwards.





3. Install the first/second gear synchronizer assembly.
1 Install the first/second gear synchronizer assembly.
2 Install a new snap-ring.

NOTE: Installation position (see step 2.).





4. Install the first gear synchronizer ring, bearing and gear.
1 Install the first gear synchronizer ring.
2 Install the needle bearing.
3 Install first gear.





5. Install the output pinion on.
1 Install the output pinion on using a suitable driver.
2 Install a new snap-ring.

CAUTION: The output pinion can only be installed on the shaft splines in one position.

NOTE: Install the output pinion with the mark facing upwards.





6. Install the bearing.
- Install the bearing using a suitable driver.





7. Install fifth gear.
1 Install the bearing.
2 Install fifth gear.
3 Install the synchronizer ring.





8. Installation position of the synchronizer assembly.

NOTE: Install the synchronizer hub with the small collar and the annular groove running round it facing outwards.





9. Install fifth/reverse gear synchronizer assembly.
1 Install the synchronizer assembly.
2 Install a new snap-ring.





10. Install reverse gear.
1 Install the synchronizer ring.
2 Install the bearing.
3 Install reverse gear.





11. Install the bearing.
- Install the bearing using a suitable driver.