Ford Falcon. Manual — part 276

308-03b-18

Manual Transmission — TR3650

308-03b-18

DISASSEMBLY (Continued)

17. Remove the OSS sensor tone wheel check ball.

20. Remove the fifth gear shift fork, synchronizer

assembly, synchronizer cone and the fifth gear as

an assembly.

18. Remove and discard the fifth gear synchronizer

retaining ring.

21. Remove the fifth gear clutch cone.

19. Using a 3.9 mm punch and a hammer, remove

and discard the pin from the fifth gear shift fork.

22. Remove the fifth gear synchronizer blocking ring.

Inspect the blocking ring for wear or damage.

Install new blocking rings as necessary.

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308-03b-19

Manual Transmission — TR3650

308-03b-19

DISASSEMBLY (Continued)

23. Remove the fifth gear synchronizer sleeve from

26. Remove the check ball.

the synchronizer hub.

27. Using a 3.9 mm punch and a hammer, drive out

24. Remove the synchronizer inserts and the springs.

the split pin, then remove the third/fourth shift

finger. Discard the split pin.

25. Remove the needle bearings and the thrust

washer.

28. Using a 3.9 mm punch and a hammer, drive out

The fifth gear needle bearing is three

the split pin, then remove the first/second shift

separate pieces: bearing, spacer, bearing.

finger. Discard the split pin.

Inspect the needle bearing for wear or

damage. Install new bearings as necessary.

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308-03b-20

Manual Transmission — TR3650

308-03b-20

DISASSEMBLY (Continued)

32. Remove the three detent plugs, springs and the

29. Remove the main shift rail and the plastic spacer.

detents.

30. Remove the bolts and the shift interlock plate.

CAUTION: Do not remove all the bolts while

in the horizontal position.
33. Remove the bolts.

Rotate the transmission to a horizontal

position. Remove 12 bolts, leaving two

opposing bolts in. Rotate the transmission to

a vertical position, then remove the remaining

two bolts.

31. Using a magnet, remove the interlock pins.

One lock pin in the center rail, two between

the rails.

34. Carefully pry the clutch housing from the

transmission main case.

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308-03b-21

Manual Transmission — TR3650

308-03b-21

DISASSEMBLY (Continued)

35. Remove the transmission main case from the

37. Remove the mainshaft and shift assembly.

clutch housing.

38. Remove the input shaft. For input shaft

36. Lift the mainshaft 13 mm upward, tilt the

disassembly, refer to Input Shaft and Bearing in

countershaft outward and remove the

this section.

countershaft.

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