What should the front drive output shaft end play be?

The end play should be 0.003–0.005 inch, checked with a dial indicator on the front drive output shaft. If not within these limits, adjust the shim pack at the front output shaft rear cover.

What tool is used to install the output shaft inner bearing?

Fig. 14 shows removal using tool OTC-951 and installation using tool T57L-4621-B, along with a press ram and wood block.

What tools are used to remove the shift rail seals?

Fig. 16 shows shift rail seal removal using tools T58L-101-A and T59L-100-B; Fig. 17 shows installation of the shift rail oil seals with tool T53L-200-A.

Where do the heavier loaded spring and flat washer go when installing shift rail detent parts?

The document states to be sure the heavier loaded spring and flat washer are installed in the front drive shift rail, then install the rod access hole plug.

Should a new O-ring be used on the output shaft flange?

Yes — the manual states to install a new O-ring in the front output shaft flange when installing the flange, washer, and retaining nut, and to torque the attaching nuts to specifications.

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Ford Bronco Transfer Case Assembly - Output Shaft Bearings & Shift Rail Seals

Ford manual transmission Group 6 assembly procedure: output shaft bearing, idler gear and shift rail oil seals

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Manual-shift transmission reassembly page (p.6-24): set front output shaft end play to 0.003-0.005 in via shim pack, install idler gear/thrust washers and new O-ring on front output shaft flange.

AI caption March 2006 · Photo 71 of 206

This is page 6-24 from a Ford shop manual section titled "GROUP 6 — Manual Shift Transmission," covering transfer case assembly procedures (uploaded as part of a multi-page transfer case set). The page contains numbered assembly steps 16 through 22: installing roller bearings in the idler shaft gear bore with vaseline or grease, positioning the idler gear and thrust washers and driving the idler shaft into the case, securing the shift rail link, installing front and rear drive shift rail detent balls/springs/plugs (with the heavier loaded spring and flat washer in the front drive shift rail), installing output shaft flanges with new O-rings, checking front drive output shaft end play with a dial indicator (0.003–0.005 inch spec, adjusted via the shim pack at the front output shaft rear cover), and installing the cover plate. Four illustrated figures show tooling: Fig. 14 (Replacing Output Shaft Inner Bearing, using press ram, wood block, tools OTC-951 and T57L-4621-B), Fig. 15 (Installing Front Output Shaft Rear Bearing, tool T57L-4621-B), Fig. 16 (Removing Shift Rail Seals, tools T58L-101-A and T59L-100-B), and Fig. 17 (Installing Shift Rail Oil Seals, tool T53L-200-A). Image reference codes C1612-A through C1615-A appear on the photos.

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Frequently asked questions

What should the front drive output shaft end play be?: The end play should be 0.003–0.005 inch, checked with a dial indicator on the front drive output shaft. If not within these limits, adjust the shim pack at the front output shaft rear cover.
What tool is used to install the output shaft inner bearing?: Fig. 14 shows removal using tool OTC-951 and installation using tool T57L-4621-B, along with a press ram and wood block.
What tools are used to remove the shift rail seals?: Fig. 16 shows shift rail seal removal using tools T58L-101-A and T59L-100-B; Fig. 17 shows installation of the shift rail oil seals with tool T53L-200-A.
Where do the heavier loaded spring and flat washer go when installing shift rail detent parts?: The document states to be sure the heavier loaded spring and flat washer are installed in the front drive shift rail, then install the rod access hole plug.
Should a new O-ring be used on the output shaft flange?: Yes — the manual states to install a new O-ring in the front output shaft flange when installing the flange, washer, and retaining nut, and to torque the attaching nuts to specifications.