Output Shaft

Disassembly





1. Use a press and the special tool to remove the third/fourth gear synchronizer, the third speed synchronizer blocking ring and third gear as an assembly.





2. Remove the second and third speed gear bearing assembly and the third speed bearing spacer.





3. Remove the fifth speed gear snap ring.





4. Using a press and the special tool, remove the fifth speed gear.





5. Remove the output shaft rear bearing.





6. Remove the first gear.





7. Note: There is a snug fit between the input bearing spacer and the output shaft.

Remove the first gear bearing and the input bearing spacer as an assembly.





8. Remove the first and second speed synchronizer hub ball.





9. Remove the first and second gear synchronizer inner cone, the first and second gear outer cone and the synchronizer blocking ring as an assembly.





10. Remove the second gear snap ring and the thrust washer.





11. Remove the second gear and the second and third speed bearing assembly.





12. Remove the first/second speed synchronizer spiral snap ring.





13. Remove the first and second gear synchronizer inner cone, the first and second gear synchronizer outer cone and the blocking ring as an assembly.
14. Remove the first and second gear synchronizer sliding sleeve.

15. Note: The first/second speed synchronizer and hub is serviced only as an assembly with the output shaft. Do not attempt to separate the hub from the output shaft. The only parts that are serviced are the synchronizer blocking springs and the synchronizer hub inserts.

Mark the alignment of the synchronizer rings to the hub. Remove the synchronizer blocking spring and hub inserts.

Assembly





1. Assemble the first/second synchronizer hub.
1 Install the synchronizer blocking spring and the synchronizer inserts into the synchronizer hub.
2 Install the sliding sleeve onto the first/second synchronizer hub.





2. Note: Align the slots in the synchronizer blocking ring with the tabs in the first/second speed synchronizer.

Install the first/second gear synchronizer sliding sleeve, the first/second gear blocking ring and the first/second gear inner and outer cones as an assembly.





3. Using the special tool, install the first/second speed synchronizer spiral snap ring.
^ Install the first/second gear thrust washer.
^ Install the spiral snap ring.





4. Install the bearing and second speed gear bearing spacer.





5. Note: Align the slots in the second gear with the tabs on the synchronizer blocking ring assembly.

Install the second gear onto the output shaft.





6. Install the thrust washer and the snap ring.





7. Note: Align the slot in the first gear synchronizer blocking ring with the tab on the first/second synchronizer.

Install the first and second gear synchronizer inner and outer cones, and the synchronizer blocking ring, as an assembly.





8. Install the first and second speed synchronizer hub ball.





9. Note: Align the notch in the first gear bearing spacer with the first and second speed synchronizer pin.

Install the first gear bearing spacer and the first gear bearing.





10. Note: Align the slots on the first gear synchronizer blocking ring with the slots on the first gear.

Install the first gear.





11. Install the rear output shaft bearing.





12. CAUTION: Make sure the output shaft splines and the splines of fifth speed gear are carefully aligned. If the splines are improperly aligned, damage could occur when the first gear is pressed onto the output shaft.

Lubricate the splines of the fifth speed gear with petroleum jelly and position on the output shaft. Using a press and a capped length of pipe 31.7 mm inside diameter X 356 mm (1-1/4 inch inside diameter X 14 inches), install the fifth speed gear.





13. Install the fifth gear snap ring.





14. Install the third speed gear spacer and the second and third speed bearing.





15. Note: Before pressing the components together, make sure the synchronizer hub faces the short end of the output shaft. Hold the third gear against the synchronizer to maintain the synchronizer blocking alignment.

Using a press and a 1-1/2 inch deep well socket, install the third/fourth synchronizer, synchronizer blocking ring and third gear.