Ford Falcon. Manual — part 277

308-03b-22

Manual Transmission — TR3650

308-03b-22

DISASSEMBLY (Continued)

39. Remove the shift rails and shift forks from the

43. Remove the reverse idler gear bearing.

main shaft. For gearshift rail and fork

The reverse idler gear is three separate

disassembly, refer to Gearshift Rail and Fork in

pieces: bearing, spacer, bearing.

this section.

Inspect the bearing for wear or damage.

Install new bearings as necessary.

40. Remove the reverse idler shaft bolt. Remove and

discard the seal.

44. Disassemble the clutch housing.

1. Remove the countershaft bearing cup and

shim.

2. Remove the input shaft bearing cup and shim.

3. Remove the input shaft seal.

Carefully pry out from the inside of the

case.

41. Remove the reverse idler gear assembly.
42. Remove the reverse idler gear from the shaft.

Inspect the gear for wear or damage. Install a

new gear as necessary.

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Manual Transmission — TR3650

308-03b-23

DISASSEMBLY (Continued)

45. Remove the rear countershaft bearing.

46. Remove the rear countershaft bearing cup and

the rear output shaft bearing cup.

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308-03b-24

Manual Transmission — TR3650

308-03b-24

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES

Input Shaft and Bearing

Special Tool(s)

Remover, Driver Pinion Bearing

Cone

205-D002 (D79L-4621-A) or

equivalent

Installer, Drive Pinion Bearing

Cone

205-011 (T57L-4621-B)

Remover/Installer, Bearing

Tube

Disassembly
1. Disassemble the input shaft.

1. Remove the third/fourth synchronizer blocking

Item

Description

ring.

1

Synchronizer blocking ring

2. Remove the input shaft thrust washer.

2

Thrust washer

3. Remove the input shaft thrust bearing.

3

Thrust bearing

4. Remove the input shaft pocket bearing.

4

Thrust washer

Inspect all components for wear or damage.

Install new components as necessary.

5

Pocket bearing

2. Using the special tool and a press, remove the

input shaft front bearing assembly. Discard the

bearing.

3. Inspect the input shaft and bearings for wear or

damage. Install new components as necessary.

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Manual Transmission — TR3650

308-03b-25

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

4. Using the special tools and a press, install the

CAUTION: Hand tighten the special tool to

new input shaft front bearing.

prevent gear damage.

CAUTION: Support the output shaft while

using the press to prevent damage to the shaft or

gears.
2. Using the special tool, press fifth gear, the spacer,

the output shaft bearing and reverse gear from

the output shaft.

Discard the output shaft bearing.

5. Install the input shaft pocket bearing, the washer,

input shaft bearing and the third/fourth

synchronizer blocking ring.

Lubricate the bearing and bearing race with

petroleum jelly.

Output Shaft

Special Tool(s)

3. Remove reverse gear needle bearing.

Remover, Drive Pinion Bearing

Inspect the needle bearing for wear or

Cone

damage. Install a new needle bearing as

205-D002 (D79L-4621-A) or

necessary.

equivalent

Installer, Drive Pinion Bearing

Cone

205-011 (T57L-4621-B)

Disassembly
1. Remove the retaining ring above fifth gear.

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