Output Shaft

Disassembly

NOTE: Steps 1 and 2 are for Mustang Cobra only. All others begin with Step 3.

1. Using Bearing Pulling Attachment D84L-1122-A or equivalent, press off input shaft-to-output shaft taper roller bearing.
   
   
   
   

2. Remove snap ring (7064) .
   
   
   
   

3. Using a press and Pinion Bearing Cone Remover D79L-4621-A or equivalent, remove third/fourth synchronizer (7124) , third speed synchronizer blocking ring (7107), and third gear (3GR) (7B340) as an assembly.
   
   
   
   

4. Remove second and third speed gear bearing (7B369) assembly and third speed gear bearing spacer (7728) from output and fifth gear drive shaft (7061) .
   
   
   
   

5. Remove fifth speed gear snap ring .
   
   
   
   

6. Using a press and Pinion Bearing Cone Remover D79L-4621-A or equivalent, remove fifth speed gear (7K316) .
   
   
   
   

7. Remove output shaft rear bearing.
   
   
   
   

8. Remove first gear.
   
   
   
   

   NOTE: There is a snug fit between the input bearing spacer (7173) and the output and fifth gear drive shaft .

9. Remove output and fifth gear drive shaft assembly and input bearing spacer .
   
   
   
   

10. Remove first and second speed synchronizer hub pin (7K218) using a pencil magnet.
    
    
    
    

11. Remove first and second gear synchronizer inner cone (7175) , first and second gear synchronizer outer cone (7174) and synchronizer blocking ring assembly from output and fifth gear drive shaft .
    
    
    
    

12. Remove second gear snap ring and thrust washer (7119) .
    
    
    
    

13. Remove second gear (2GR) (7102) from output and fifth gear drive shaft .
    
    
    
    

14. Remove second and third speed gear bearing assembly and second speed gear bearing spacer (7B320) .
    
    
    
    

15. Disengage output shaft bearing to case snap ring (7160) from slot in output and fifth gear drive shaft using a small screwdriver.
    
    
    
    

16. Remove output shaft bearing to case snap ring and first and second speed synchronizer thrust washer (7117) from output and fifth gear drive shaft .
    
    
    
    

17. Remove first and second gear synchronizer inner cone , first and second gear synchronizer outer cone and synchronizer blocking ring assembly.

    Remove first/second synchronizer from output and fifth gear drive shaft .
    
    
    
    

    NOTE: The first/second speed synchronizer and hub is serviced only as an assembly with the output and fifth gear drive shaft . No attempt should be made to separate the hub from the output and fifth gear drive shaft .

18. The synchronizer blocking spring (7109) and synchronizer hub inserts (7A044) may be removed from the hub after scratching or etching alignment marks on the hub and synchronizer . The only parts that can be serviced are the springs and synchronizer hub inserts . If the hub or sleeve is worn or damaged, the output and fifth gear drive shaft and synchronizer must be replaced as an assembly. Refer to Synchronizer Disassembly and Assembly.
    
    
    
    

Assembly

1. Install synchronizer hub inserts in first/second synchronizer hub on output and fifth gear drive shaft .
   
   
   
   

2. Install first/second synchronizer assembly, first and second gear synchronizer inner cone , first and second gear synchronizer outer cone and synchronizer blocking ring assembly onto output and fifth gear drive shaft .

   NOTE: Align slots in synchronizer blocking ring with tabs in first/second synchronizer .

   For synchronizer assembly, refer to Synchronizer Disassembly and Assembly.
   
   
   
   

3. Install first and second speed synchronizer thrust washer onto output and fifth gear drive shaft . Install output shaft bearing to case snap ring using Spiral Snap Ring Replacer T85P-7025-A.
   
   
   
   

4. Install second and third speed gear bearing and second speed gear bearing spacer .
   
   
   
   

5. Install second gear onto output and fifth gear drive shaft .

   NOTE: Align slots in second gear with tabs on synchronizer blocking ring assembly.

   
   
   
   
   

6. Install second gear snap ring and thrust washer using snap ring pliers.
   
   
   
   

7. Install first and second gear synchronizer inner cone , first and second gear synchronizer outer cone and synchronizer blocking ring assembly onto output and fifth gear drive shaft .

   NOTE: Align slot in first gear synchronizer blocking ring with tab on first/second synchronizer .

   
   
   
   
   

8. Drop first and second speed synchronizer hub pin into output and fifth gear drive shaft .

   NOTE: Use pencil magnet if necessary.

   
   
   
   
   

9. While aligning notch in input bearing spacer with first and second speed synchronizer hub pin , slide input bearing spacer onto output and fifth gear drive shaft .

   Install needle bearing assembly over input bearing spacer .
   
   
   
   

10. Install first gear (1GR) (7100) onto output and fifth gear drive shaft .

    NOTE: Align slots in first gear with tabs on first gear synchronizer blocking ring assembly.

    
    
    
    
    

     CAUTION: Ensure the output and fifth gear drive shaft and first gear splines are carefully aligned. If splines are improperly aligned, damage could occur when the first gear is pressed onto the output and fifth gear drive shaft .

11. Install rear output shaft bearing onto output and fifth gear drive shaft . The bearing taper must face the rear of the output and fifth gear drive shaft .
    
    
    
    

12. Lubricate fifth speed gear splines with petroleum jelly and position on output and fifth gear drive shaft . Using a press and a capped length of pipe, 31.75mm ID x 356mm (1-1/4 inch ID x 14 inch), press fifth speed gear onto output and fifth gear drive shaft .
    
    
    
    

13. Using snap ring pliers, install fifth speed gear snap ring .
    
    
    
    

14. Install third speed gear bearing spacer and second and third speed gear bearing assembly onto output and fifth gear drive shaft .
    
    
    
    

    NOTE: Before pressing components together, ensure the synchronizer hub faces the short end of the output and fifth gear drive shaft . Hold third gear against the synchronizer to maintain synchronizer blocking ring alignment.

15. Using a press and a 1-1/2 inch-deep well socket, install third/fourth synchronizer , synchronizer blocking ring and third gear as an assembly.
    
    
    
    

16. For Mustang Cobra, install snap ring .
    
    
    
    

     CAUTION: Make sure bearing is fully seated against snap ring or damage to components could result.

17. For Mustang Cobra, press on input shaft-to-output shaft taper roller bearing.