Ford Falcon. Manual - part 278

308-03b-26 

Manual Transmission — TR3650 

308-03b-26

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

4.  Remove the check ball and the blocking ring.

6.  Remove the first gear needle bearing.

Inspect the blocking ring for wear or damage.

Inspect the needle bearing for wear or

Install new blocking rings as necessary.

damage. Install a new needle bearing as

necessary.

7.  Remove the first gear synchronizer inner cone,

the first gear synchronizer outer cone and the first

gear synchronizer blocking ring.

Inspect all components for wear or damage.

Install new components as necessary.

5.  Using the special tools, press the bearing spacer,

the reverse gear synchronizer cone and first gear

from the output shaft.
NOTE: Install the special tool with the flat side

facing first gear.

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308-03b-27 

Manual Transmission — TR3650 

308-03b-27

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

8.  Remove and discard the retaining ring.

11. Remove the third gear.

NOTE: Reposition the output shaft on the press

Inspect the gear for wear or damage. Install a

with the input shaft end facing upward.

new gear as necessary.

12. Remove the third gear needle bearing.

9.  Remove the third/fourth synchronizer hub.

Inspect the needle bearing for wear or

damage. Install a new needle bearing as

necessary.

10. Remove the third/fourth blocking ring.

NOTE: Install the special tool behind second gear

with the flat side of the tool facing second gear.

13. Using the special tool, remove the spacer, second

gear thrust washer and second gear.

Inspect the gear for wear or damage. Install a

new gear as necessary.

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308-03b-28 

Manual Transmission — TR3650 

308-03b-28

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

14. Remove the check ball and second gear needle

Assembly

bearing.

1.  Carry out the following before reassembling:

Inspect the needle bearing for wear or

Inspect the gears for broken or cracked teeth.

damage. Install a new needle bearing as

Check for unusual wear patterns.

necessary.

Inspect the thrust washers for face wear,

cracks, scoring and for signs of heat damage.
Inspect the bearings, bearing cups and the

synchronizers for wear or damage.
Inspect the output shaft for scoring or worn or

damaged splines. Install new components as

necessary.

2.  Lubricate all components with the recommended

transmission fluid when reassembling.

NOTE: Position the output shaft with the output end

facing upward.

NOTE: Install the synchronizer assembly with the

deeper center flange of the synchronizer hub facing

toward the rear of the output shaft.

15. Remove the second gear synchronizer inner

cone, second gear synchronizer outer cone and

3.  Install the first/second synchronizer assembly on

the second gear synchronizer blocking ring.

the output shaft, then install a new retaining ring.

Inspect all components for wear or damage.

It may be necessary to press the hub into

Install new components as necessary.

position on the shaft.

16. Remove the snap ring, then using the special tool,

press off the first/second gear synchronizer.

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308-03b-29 

Manual Transmission — TR3650 

308-03b-29

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

4.  Install the first gear synchronizer blocking ring.

7.  Install the first gear needle bearing.

Align the blocking ring tabs with the

Apply petroleum jelly to the bearing.

synchronizer assembly.

8.  Install first gear.

5.  Install the outer first gear synchronizer cone.

Rotate the gear to align the gear slots with the

inner cone tabs.

6.  Install the inner first gear synchronizer cone.

Rotate the inner cone till it is seated.

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