Output Shaft

Output Shaft





Special Tool(s)





Material








Output Shaft

Disassembly

CAUTION: The inner synchronizer ring and the synchronizer cone must be handled very carefully.





1. CAUTION: Loosely attach the special tool to avoid damaging the
synchronizer ring.

Using a suitable press and the special tool, remove the output shaft bearing and the reverse gear. Discard the output shaft bearing.





2. Remove the reverse gear needle bearing and the synchronizer ring.





3. Remove the fifth reverse gear synchronizer assembly.
^ Remove and discard the snap ring, and remove the synchronizer assembly.





4. Remove the synchronizer ring, fifth gear and fifth gear needle bearing.





5. NOTE: Position the special tool with the flat side upward.

Using the special tool, remove and discard the snap ring, then remove the fourth gear.





6. NOTE: Position the special tool with the flat side upward. Using the special tool, remove the second and the third gear.





7. CAUTION: Be extremely careful when handling the inner synchronizer ring and synchronizer cone.

Remove the following:
1. The outer synchronizer ring.
2. The synchronizer cone.
3. The inner synchronizer ring.
4. Second gear.
5. Second gear needle bearing.





8. Remove and discard the snap ring, then remove the first and the second gear synchronizer hub assembly.





9. CAUTION: Be extremely careful when handling the inner synchronizer ring and synchronizer cone.

Remove the following:
1. The outer synchronizer ring.
2. The inner synchronizer ring.
3. The synchronizer cone.
4. First gear.
5. First gear needle bearing.





10. Using the special tool, remove the clutch housing roller bearing.





11. NOTE: Mark the installed position of the selector ring.

Disassemble the first/second and fifth reverse synchronizer hub assemblies. Remove the selector ring from the synchronizer hub. Remove the compression springs, the keys and the detent balls.
^ Take care when pulling the selector ring from the synchronizer hub. The detent balls are spring-loaded.
12. Inspect the synchronizer assemblies.
^ Check for worn, nicked or broken teeth. Install a new synchronizer as necessary.
^ Check keys for wear or distortion. Install a new synchronizer as necessary.
^ Check springs for distortion. Install a new synchronizer as necessary.

Assembly

1. NOTE: Do not lubricate new roller bearings.

Lubricate all transmission components with transmission fluid during reassembly.





2. CAUTION: Handle the inner synchronizer ring and synchronizer cone very carefully.

Install the following:
1. The first gear needle bearing.
2. First gear.
3. The inner synchronizer ring.
4. The synchronizer cone.
5. The outer synchronizer ring.





3. NOTE: Observe the markings on the selector ring.

Assemble the synchronizer hub assembly.
1. Install the compression springs.
2. Install the keys and the detent balls in the gear synchronizer hub against the force of the spring.
3. Align the selector ring with the hub and push it on.





4. NOTE: Install the synchronizer hub assembly with the larger collar facing toward second gear.

Install the first/second gear synchronizer hub assembly, then install a new snap ring.





5. Install the following:
1. The second gear needle bearing.
2. The outer synchronizer ring.
3. The synchronizer cone.
4. The inner synchronizer ring.
5. Second gear.





6. Using a suitable press and the special tool, install third gear.





7. Using a suitable press and the special tool, install fourth gear. Install a new snap ring.





8. Install the fifth gear needle bearing, fifth gear and the synchronizer ring.





9. NOTE: Install the synchronizer hub assembly with the small collar and the ring groove facing outward.

Install the fifth reverse gear synchronizer assembly. Install a new snap ring.





10. Install the synchronizer ring, the reverse gear needle bearing and the reverse gear.





11. Using a suitable press, install a new output shaft bearing.





12. Using a suitable press, install a new output shaft bearing.