Output Shaft

Output Shaft

















Disassembly

NOTICE: Hand-tighten the Bearing Puller to prevent gear damage.

NOTICE: Support the output shaft while using the press to prevent damage to the shaft or gears.

1. Remove the 5th/6th gear synchronizer assembly snap ring.





2. Using the Bearing Puller and a hydraulic press, remove the 5th/6th gear synchronizer assembly.
- Inspect the 5th/6th gear synchronizer assembly and the 6th gear synchronizer ring and cone for wear or damage. Install new components as necessary.





3. Remove the 6th gear.
- Inspect the 6th gear for wear or damage. Install a new gear as necessary.





4. Remove the 6th gear needle bearing.
- Inspect the 6th gear needle bearing for wear or damage. Install a new needle bearing as necessary.





5. Inspect the output shaft for scoring or worn or damaged splines. Install a new output shaft as necessary.

Assembly

NOTICE: Lubricate all components with the recommended transmission fluid before reassembling.

1. Position the 5th/6th gear synchronizer assembly on the Bearing Puller and a hydraulic press.





2. NOTICE: The 3 synchronizer ring tabs must engage into the 3 synchronizer assembly slots or damage to the synchronizer assembly and synchronizer ring can occur.

Install the 6th gear synchronizer ring and cone.

- Align the 3 synchronizer ring tabs with the 3 synchronizer assembly slots.





3. Install the 6th gear needle bearing.





4. Install the 6th gear.





5. Using the Bearing Puller and a hydraulic press, install the 5th/6th gear synchronizer assembly and the 6th gear.





6. Install the 5th/6th gear synchronizer assembly snap ring.