2. Main Shaft and Input Shaft Disassemble

Main Shaft and Input Shaft Disassemble

Special Tools
* J 22912-B - Rear Pinion and Axle Bearing Remover Split Plate
* J 36513 - Split Plate
* J 39442 - Press Adapter
* J 39443 - Bearing Remover Split Plate
* J 39473 - Mainshaft Bearing Installer
* J 39594 - Bearing Race Remover
* J 45124 - Removal Bridge

For equivalent regional tools, refer to Special Tools (Special Tools and Equipment).

Mainshaft





Note: Measure the 4th speed gear synchronizer wear gap before disassembling the mainshaft.

1. Install the input shaft (3) in the clutch housing (4).
2. Install the mainshaft (1) on the input shaft (3).
3. Using a feeler gauge measure the gap (2) between the 4th speed gear blocking ring and the 4th speed gear.
4. Replace the 4th speed gear friction cone and blocking ring when the gap is less than 1.27 mm (0.050 in).





Caution: Do not overtighten the J 36513 split plate past the gear teeth or damage to gear may occur.

5. Using the J 36513 - plate , close the split plate only enough to support the gear teeth, and the J 39442 - adapter , remove the following parts in order:

1. The 6th speed driven gear (1)
2. The mainshaft center bearing (2)
3. If an O-ring is present on the mainshaft, remove and discard the O-ring (3). The O-ring was used for manufacturing purposes only.
4. The 1st speed drive gear (4)
5. The 1st speed drive gear needle bearing (5)




6. Remove the following parts in order:

1. The 1st speed gear inner cone (1)
2. The 1st speed gear outer cone (2)
3. The 1st speed gear synchronizer blocking ring (3)
4. The 1st speed gear locking ring (4)
5. The 1st speed gear two piece washer (5)





Note: The synchronizer hubs and sliding sleeves are a selected assembly. Keep these parts together as originally assembled.

7. Scribe a mark on the synchronizer hub and on the sleeve. This will help you to reinstall the parts in the same position.




8. Use the J 36513 - plate (2) in an inverted position, J 39442 - adapter (1), and a hydraulic press to remove the following components:

* The 2nd speed drive gear (3)
* The 2nd speed gear inner cone (4) will press off with the 2nd speed gear
* The 2nd speed gear outer cone (5)
* The 2nd gear synchronizer blocking ring (6)
* 1st/2nd synchronizer hub (7)




9. Remove the 2nd speed gear spacer (1) and caged needle bearing (2).




10. Remove the mainshaft small tapered bearing (3). Use the J 39442 - adapter (1), the J 39443 - plate (2), and a hydraulic press.
11. Discard the small tapered bearing.




12. Remove the retainer (1).





Note: The synchronizer hubs and sliding sleeves are a selected assembly. Keep these parts together as originally assembled.

13. Scribe a mark on the synchronizer hub and on the sleeve. This will help you to reinstall the parts in the same position.




14. Use the J 39473 - installer (1), V-blocks, and a hydraulic press to remove the following components:

* The 3rd/4th speed synchronizer assembly (6)
* The 3rd speed gear blocking ring (5)
* The 3rd speed gear outer cone (4)
* The 3rd speed gear inner cone (3)
* The 3rd speed gear (2)




15. Remove the 3rd speed drive gear spacer (1).
16. Remove the 3rd speed gear caged needle bearing (2).

Input Shaft

Note: Do not replace the tapered bearing or the bearing race unless inspection shows that the bearing or the race are damaged.




1. Remove the tapered bearing from the input shaft, using the J 22912-B - bearing remover and a hydraulic press.




2. Remove the bearing race from the input shaft, using the J 45124 - bridge (1) and the J 39594 - race remover (2).