Output Shaft - Reassemble

Output Shaft - Reassemble







1. Clamp output shaft in protected vice jaws, output end upwards.
2. Fit 2nd gear needle roller bearing, 2nd gear and synchromesh baulk rings on to output shaft.

NOTE: Rotate each baulk ring to ensure they locate onto each other.

3. Assemble the 1st and 2nd synchromesh selector hub on to output shaft splines, noting the 2nd gear side marking. Ensure that baulk ring has located correctly inside hub.

NOTE: Rotate the ring slightly as the hub is lowered.

4. Fit 1st gear synchromesh baulk rings, needle roller bearing, 1st gear and bush on to output shaft ensuring baulk rings locate correctly inside selector hub.
5. Using LRT-99-002, and a suitable mandrel positioned on bearing inner race, press on output shaft taper roller bearing taking care not to disturb the position of the synchromesh baulk rings and gears.
6. Check 1st and 2nd gear end-float.







Checking 1st gear end-float
New: 0.05 - 0.20 mm (0.002 - 0.008 in)
Service limit: 0.327 mm (0.012 in)







Checking 2nd gear end-float
New: 0.04 - 0.21 mm (0.0016 - 0.008 in)
Service limit: 0.337 mm (0.013 in)

7. Invert output shaft in vice and fit 3rd gear needle roller bearing, third gear and synchromesh baulk rings.
8. Assemble 3rd/4th gear synchromesh selector hub, noting 3rd speed side markings, on to output shaft splines taking care to locate the baulk rings into recesses in the selector hub.
9. Fit spacer.







10. Using LRT-99-002 and a suitable mandrel positioned on bearing inner race, press on new pilot bearing.
Check end float of 3rd gear.







Checking 3rd gear end-float
New: 0.11 - 0.21 mm (0.004 - 0.008 in)
Service limit: 0.337 mm (0.013 in)