Ford Falcon. Manual — part 267

308-03a-30

Manual Transmission — I6

308-03a-30

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

10. Remove ball using a pencil magnet.

7. Remove output shaft rear bearing.

NOTE: There is a snug fit between the sleeve and

the output shaft.

11. Remove three-piece first gear synchronizer

blocking ring assembly from output shaft.

8. Remove first gear.

12. Remove second gear snap ring and thrust

washer.

9. Remove needle bearing assembly and sleeve.

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308-03a-31

Manual Transmission — I6

308-03a-31

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

16. Remove spiral snap ring and thrust washer from

13. Remove second gear from output shaft.

output shaft.

14. Remove second gear needle bearing assembly

17. Remove three-piece second gear synchronizer

and spacer.

blocking ring assembly.

Remove 1st/2nd synchronizer from output shaft.

15. Disengage spiral snap ring from slot in output

shaft using a small screwdriver.

Assembly
1. Install 1st/2nd synchronizer assembly, and

three-piece 2nd gear synchronizer blocking ring

assembly onto output shaft.
NOTE: Align slots in synchronizer blocking ring

with tabs in 1st/2nd synchronizer.
For synchronizer assembly, refer to Synchronizer

Disassembly and Assembly.

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308-03a-32

Manual Transmission — I6

308-03a-32

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

2. Install thrust washer onto output shaft. Install

5. Install second gear thrust washer and snap ring

spiral snap ring using Spiral Snap Ring Replacer.

using snap ring pliers.

3. Install second gear needle bearing and spacer.

6. Install three-piece first gear synchronizer blocking

ring assembly onto output shaft.
NOTE: Align slot in first gear synchronizer

blocking ring with tab on 1st/2nd synchronizer.

4. Install second gear onto output shaft.

NOTE: Align slots in second gear with tabs on

synchronizer blocking ring assembly.

7. Drop ball into output shaft.

NOTE: Use pencil magnet if necessary.

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308-03a-33

Manual Transmission — I6

308-03a-33

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

8. While aligning notch in sleeve with ball, slide

11. Lubricate fifth gear splines with petroleum jelly

sleeve onto output shaft. Install needle bearing

and position on output shaft. Using a press and a

assembly over sleeve.

capped length of pipe, 31.75mm ID x 356mm (1 1

/4 inch ID x 14 inch) press fifth gear onto output

shaft.

9. Install first gear onto output shaft.

NOTE: Align slots in first gear with tabs on first

gear synchronizer blocking ring assembly.

12. Using snap ring pliers, install fifth gear snap ring.

10. Install rear output shaft bearing onto output shaft.

The bearing taper must face the rear of the shaft.

CAUTION: Ensure the output shaft and gear

splines are carefully aligned. If splines are

improperly aligned, damage could occur when the

gear is pressed onto the output shaft.

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