Main Shaft and Input Shaft Assemble

Main Shaft and Input Shaft Assemble


Tools Required
* J 25234 Press Tube
* J 28537-17 Bearing Race Installer
* J 36183 Press Tube
* J 36184 Press Tube Adapter
* J 39371 1st/2nd Synchronizer Installer
* J 39441 5th/6th Driven Gear Installer
* J-39441-20 5th Gear Installer Adapter
* J 39473 Mainshaft Bearing Installer



Mainshaft




1. Install the 3rd speed gear caged needle bearing.
2. Install the spacer.




3. Check the 3rd/4th speed gear synchronizer assembly scribe marks for correct positions.




4. Install the 3rd/4th synchronizer assembly as follows:

1. Start the press operation.
2. STOP pressing before the keys engage the blocking ring slots.
3. Lift and rotate the 3rd speed gear in order to engage the keys with the blocking ring.
4. Continue pressing until the synchronizer is seated.

5. Install the following parts in order, using the J 36183 , the J 36184 , and a hydraulic press:

1. The 3rd speed gear
2. The 3rd speed gear inner cone
3. The 3rd speed gear friction cone
4. The 3rd speed gear blocking ring
5. The 3rd/4th speed gear synchronizer assembly (the groove on the sleeve faces the 3rd speed gear).





6. Install the 3rd/4th synchronizer retainer ring.




7. Install a new mainshaft small tapered bearing, using the J 39473 and a rubber mallet.




8. Install the 2nd speed gear caged needle bearing and bearing spacer.




9. Do the following when installing the 1st/2nd synchronizer assembly:

1. Start the press operation.
2. Stop pressing before the keys engage the blocking ring slots.
3. Lift and rotate the 2nd speed gear in order to engage the keys with the blocking ring.
4. Continue pressing until the synchronizer is seated.

10. Install the following parts in order using the J 39371 and a hydraulic press:

1. The 2nd speed gear
2. The 2nd speed gear inner cone
3. The 2nd speed gear friction cone
4. The 2nd speed gear blocking ring
5. The 1st/2nd synchronizer assembly (The ID groove on the sleeve faces the 1st speed gear.)





11. Install the following parts in order:

1. The two piece thrust washer
2. The blocking ring
3. The friction cone
4. The inner cone





12. Install the following parts in order:

1. The 1st speed gear locking ring
2. The 1st speed gear caged needle bearing
3. The 1st speed gear

13. Using J 39441 and J-39441-20 , install the mainshaft large tapered bearing.




14. Using J 39441 and J-39441-20 , install the 6th speed gear.




Input Shaft




1. Install a new bearing race on the input shaft, using the J 28537-17 and a hydraulic press.




2. Install a new tapered bearing on the input shaft. Use the J 25234 and a hydraulic press.