Ford Falcon. Manual - part 280

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Manual Transmission — TR3650 

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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

24. Press the bearing spacer onto the output shaft.

25. Install the third gear bearing.

Apply petroleum jelly to the bearing.

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Manual Transmission — TR3650 

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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

26. Install third gear.

27. Install the third gear synchronizer blocking ring.

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Manual Transmission — TR3650 

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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

28. Install the third/fourth gear synchronizer body.

Countershaft Bearing

Install the synchronizer body with the raised

center facing downward.

Special Tool(s)

Rotate the blocking ring until seated.

Remover, Drive Pinion Bearing

Cone

205-D002 (D79L-4621-A) or

equivalent

Installer, Drive Pinion Bearing

Cone

205-011 (T57L-4621-B)

Disassembly
1.  Cut the outer cage, then remove the outer cage

and rollers.

29. Install a new retaining ring.

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

inner bearing.

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Manual Transmission — TR3650 

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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

3.  Using the special tools, install the new

Gearshift Rail Bushing

countershaft bearing.

Special Tool(s)

Universal Puller Set

303-DS005 (D80L-100-A) or

equivalent

Installer, Shift Rail Bushing

308-244 (T96P-7025-F)

Synchronizers

Slide Hammer

Disassembly

100-001 (T50T-100-A)

NOTE: This procedure applies to all synchronizer

assemblies.

1.  Scribe an alignment mark on the sliding sleeve

and the hub for assembly reference.

2.  Remove the sliding sleeve, then remove the

synchronizer struts and the springs.

Disassembly
1.  Using the special tools, remove the gearshift rail

bearing from the transmission case. Discard the

bearing.

3.  Install the synchronizer struts and the springs.
4.  Install the sliding sleeve.

 CAUTION: Match the alignment marks

made during disassembly. The sleeve and the

hub have an extremely close fit. Hold the

sleeve and hub square to prevent jamming. Do

not force the sleeve onto the hub.

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