Main Shaft and Input Shaft Assemble
Main Shaft and Input Shaft Assemble
Special Tools
* 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 - Press Tube, the J 36184 - Press Tube Adapter , 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 - Mainshaft Bearing Installer 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 - 1st/2nd Synchronizer Installer 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 2nd 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 - 5th/6th Driven Gear Installer and J-39441-20 - 5th Gear Installer Adapter, install the mainshaft large tapered bearing.
14. Using J 39441 - 5th/6th Driven Gear Installer (1) and J-39441-20 - 5th Gear Installer Adapter (2), install the 6th speed gear.
Input Shaft
1. Install a new bearing race on the input shaft, using the J 28537-17 - Bearing Race Installer and a hydraulic press.
2. Install a new tapered bearing on the input shaft. Use the J 25234 - Press Tube and a hydraulic press.