Output Shaft: Disassembly

1996 Ford Contour Sport, 2.0 Z, StandardSECTION Disassembly
  1. Using a press and split clamp plate, remove tapered roller rear bearing from reverse gear end of shaft. Slide reverse gear, needle bearing and 5th-reverse synchronizer blocker ring from shaft. Remove 5th-reverse synchronizer snap ring. Slide synchronizer assembly, blocker ring, needle bearing and 5th gear from shaft. See Figure.
  2. Using a press and split clamp plate, remove tapered roller bearing from 1st gear end of shaft. Remove pinion gear snap ring. Place split clamp plate behind 1st gear and press pinion drive gear and 1st gear off shaft together.
  3. Remove needle bearing and 1st gear synchronizer blocker ring. See Figure. Remove 1st-2nd synchronizer snap ring. Slide 1st-2nd synchronizer assembly, blocker ring needle bearing and 2nd gear from shaft.
RENDER: 1.0x

NO RELATED

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • β€’ You smell fuel, burning insulation, or see smoke.
  • β€’ Brakes feel soft, pull hard to one side, or make grinding noises.
  • β€’ The engine overheats, stalls repeatedly, or misfires under load.
  • β€’ You are missing required tools, torque specs, or safe lifting equipment.
  • β€’ You are not confident in the next step or safety outcome.