Ford Falcon. Manual — part 268

308-03a-34

Manual Transmission — I6

308-03a-34

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

13. Install spacer and split needle bearing assembly

15. Install snap ring.

onto output shaft.

16. Press on input shaft-to-output shaft taper roller

14. Using a press and a 1 1 /2 inch deep well socket,

bearing.

install 3rd/4th synchronizer, third gear

synchronizer blocking ring and third gear as an

CAUTION: Make sure bearing is fully

assembly.

seated against snap ring.

NOTE: Before pressing components together,

ensure the synchronizer hub faces the short end

of the output shaft. Hold third gear against the

synchronizer to maintain synchronizer blocking

ring alignment. Ensure that 3rd speed gear is fully

seated against the thrust washer after assembly.

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308-03a-35

Manual Transmission — I6

308-03a-35

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

1. Using a press and Remover Tube and Mainshaft

Countershaft Bearing — Front

Front Bearing Replacers and Countershaft Front

Bearing Replacer (assembled to support case),

Special Tool(s)

remove bearing race with O-ring from case.

Pinion Bearing Cone Replacer

CAUTION: Failure to properly support the

205-411

case will result in permanent distortion of

case during bearing race removal.

Remover Tube

308-262

Countershaft Front Bearing

Replacer

308-262

Disassembly
NOTE: Remove the front countershaft bearing race

only if it is worn or damaged. If the bearing race is

removed, Sealer or equivalent must be used during

installation.

Assembly
1. Install O-ring onto bearing race. Coat bearing race

outside diameter with Sealer or equivalent and

position bearing race to case.

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308-03a-36

Manual Transmission — I6

308-03a-36

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

2. Using Pinion Bearing Cone Replacer and

Remover/Replacer Tube, support transmission

case on press. Press bearing race until flush with

case.

NOTE: The first/second gear synchronizer is available

only as an assembly with the output shaft. The

synchronizer hub is pressed onto the output shaft with

an interference fit; therefore, no attempt should be

made to separate the hub from the shaft. The

retaining springs, inserts, detent ball and spring are

Synchronizers

available for service. If the hub or sleeve is worn, the

Disassembly

output shaft and synchronizer must be replaced as an

assembly.

NOTE: The following procedures apply to all

synchronizer assemblies. The gear synchronizers are

slightly different in design. Notation is made where

procedural differences occur.

1. Before disassembling the synchronizer, scribe

alignment marks on the sleeve and hub for

assembly reference.

2. Using a screwdriver, remove the two synchronizer

retaining springs. Remove the inserts.

Assembly
NOTE: When assembling a synchronizer sleeve and

hub, match the alignment marks made during

disassembly. The sleeve and hub have an extremely

close fit and must be held square during assembly to

prevent jamming. Do not force the sleeve onto the

hub.

1. Assemble the inserts and synchronizer retaining

springs onto the sleeve and hub. The retaining

springs engage the same insert but rotate in

opposite directions.

2. On fifth gear synchronizer only, install the

Reverse Blocking Ring into the synchronizer.

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308-03a-37

Manual Transmission — I6

308-03a-37

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

3. Assemble retaining springs, inserts and sleeve

2. Rotate shifter shaft counterclockwise. When the

onto hub. Refer to illustration in Step 1 for

selector arm disengages from the selector arm

positioning of the retaining springs and inserts.

plate, pull shifter shaft rearward. The selector arm

roll pin will now be accessible.

Remove selector arm roll pin using a 5mm

(3/16-inch) diameter pin punch and remove the

shifter shaft.

Shift Cover

Disassembly
1. Mark shift forks for assembly reference. Position

selector arm plates and selector arm in the

NEUTRAL position. The gearshift selector arm

plates should now be centered over the control

selector arm.

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