Input Shaft

Fig. 174 Input Shaft Cross Section:

Fig. 175 5th Gear and Synchronizer Removal:

INPUT SHAFT / DISASSEMBLY
1. Remove 5th gear and synchronizer from input shaft using Tool 8919 and bearing splitter (Fig. 175).

Fig. 176 5th Gear Needle Bearing Removal:

Fig. 181 Input Shaft Disassembly/Assembly:

2. Remove 5th gear needle bearing (Fig. 176) (Fig. 181).

Fig. 177 Bushing, 3rd/4th Gear and Synchronizer Removal:

3. Remove 3rd & 4th gears, synchronizer, and 5th gear bearing bushing using Tool 8919 and bearing splitter (Fig. 177).

Fig. 178 3rd Gear Needle Bearing Removal:

Fig. 179 3rd Gear Thrust Washer Removal:

4. Remove both 3rd gear needle bearings and thrust washer (Fig. 178) (Fig. 179).

Fig. 180 Thrust Plate Removal:

5. If necessary, remove 3rd gear thrust plate (Fig. 180).

Fig. 181 Input Shaft Disassembly/Assembly:

Fig. 182 Input Shaft Cross Section:

Fig. 183 3rd Gear Thrust Bearing Installation:

ASSEMBLY

1. Install 3rd gear thrust washer (Fig. 183),(Fig. 182).

Fig. 184 3rd Gear Needle Bearing Installation:

2. Install 3rd Gear needle bearings (Fig. 184).

Fig. 185 3rd Gear Installation:

3. Install 3rd gear (Fig. 185).

Fig. 186 3rd Gear Blocker Ring Installation:

4. Install 3rd gear blocker ring (Fig. 186).

Fig. 187 3rd Gear Thrust Bearing Installation:

5. Install 3rd gear thrust bearing (Fig. 187).
6. Install 3rd gear thrust washer.
7. Install 3rd/4th gear synchronizer to shaft.

Fig. 188 3/4 Synchro Installation:

NOTE: Before pressing synchronizer onto shaft, lift upward on 3rd gear and blocker ring to engage the guides of the blocker ring to the recesses of the synchronizer body (Fig. 188). Press synchronizer into place using Tool 6448A.

Fig. 189 4th Gear Blocker Ring Installation:

8. Install 4th gear blocker ring (Fig. 189), engaging guides in ring to recesses in synchronizer body.

Fig. 190 Install 4th Gear Bushing:

Fig. 191 4th Gear Bushing Installation:

9. Install and press 4th gear needle bearing bushing using Tool 8922 (Fig. 190) (Fig. 191).

Fig. 192 Install 4th Gear Needle Bearing:

10. Install 4th gear needle bearing (Fig. 192).

Fig. 193 Install 4th Gear:

11. Install 4th gear (Fig. 193).

Fig. 194 Install 5th Gear Bushing:

12. Install 5th gear bushing (Fig. 194).

Fig. 195 Install 5th Gear Needle Bearing:

13. Install 5th gear needle bearing (Fig. 195).

Fig. 196 Install 5th Gear:

14. Install 5th gear (Fig. 196).

Fig. 197 Install 5th Gear Blocker Ring:

15. Install 5th gear blocker ring (Fig. 197).

Fig. 198 Install 5th Gear Synchronizer:

Fig. 199 5th Gear Synchronizer Installation:

16. Install 5th gear synchronizer to shaft (Fig.198). Position Tool 8922 over synchronizer and begin press operation. While pressing synchronizer onto shaft, lift upward on 5th gear and blocker ring to engage the guides of the blocker ring to the recesses of the synchronizer body (Fig. 199).