Ford Falcon. Manual - part 283

308-03b-46 

Manual Transmission — TR3650 

308-03b-46

ASSEMBLY (Continued)

33. Install the detent plugs.

36. Install the synchronizer springs and inserts.

34. Install the check ball.

37. Install the sliding sleeve on the synchronizer hub.

Use petroleum jelly to hold the check ball in

Align the pockets in the blocking ring with the

place.

struts in the synchronizer.
The sliding sleeve is not reversible. Install the

sleeve with the bevel edge away from the

gear.

35. Install the thrust washer and the three-piece fifth

gear needle bearing.

38. Install fifth gear blocking ring.

G34245 en

308-03b-47 

Manual Transmission — TR3650 

308-03b-47

ASSEMBLY (Continued)

39. Install the fifth gear synchronizer cone.

42. Install a new snap ring.

40. Install the fifth gear shift fork, the synchronizer

43. Install the third/fourth shift finger, then install a

assembly, the synchronizer cone and fifth gear as

new split pin.

an assembly.

Install the split pin until it is flush with the shift

finger.

41.  Install a new split pin.

Install the pin until it is flush with the fork.

44. Install the control rail and the plastic spacer, then

install the first/second shift finger. Install a new

split pin.

Install the split pin until it is flush with the shift

finger.

G34245 en

308-03b-48 

Manual Transmission — TR3650 

308-03b-48

ASSEMBLY (Continued)

45. Install the OSS sensor tone wheel check ball.

48. Install the fifth/reverse gear lockout.

Use petroleum jelly to hold the check ball in

place.

49. Install the bolt.

46. Place the OSS sensor tone wheel on the output

shaft, aligning the slot in the OSS wheel with the

check ball. Using the special tool, install the OSS

sensor tone wheel.

50. Clean the mating surfaces of the transmission

main case and the extension housing. Apply a

bead of silicone rubber to the sealing surface of

the transmission case.

47. Install a new OSS sensor tone wheel retaining

ring.

G34245 en

308-03b-49 

Manual Transmission — TR3650 

308-03b-49

ASSEMBLY (Continued)

51. Install the extension housing and at the same time 55. Using the special tool, install a new extension

install the gear shift off-set lever.

housing seal.

Lubricate the seal with transmission fluid.

52. Install the shift spring and bracket.

53. Install a new split pin in the gear shift off-set lever. 56. Install the shipping seal.

The split pin should be flush in the gear shift

off-set lever.

54. Seat the extension housing and tighten the bolts

to specification.

Fill the gear shift off-set lever with petroleum

jelly.

57. Rotate the transmission to a horizontal position.
58. Clean the mating surfaces of the shift cover

opening surface and the shift cover. Apply a bead

of silicone rubber to the shift cover opening

surface.

G34245 en