Output Shaft

Fig. 200 Output Shaft Section View:

Fig. 201 4th/5th Gear Removal:

OUTPUT SHAFT / DISASSEMBLY
1. Install output shaft to fixture 8925-3. Use split plate 8925-2 on diesel models, and 8925-4 on turbo models as shown in (Fig. 201).
2. Remove 4th and 5th gears simultaneously. Install protective sleeve 8918 to output shaft and press 4th and 5th gears off of shaft (Fig. 201).

Fig. 202 3rd Gear Removal:

3. Install output shaft to fixture 8925-3 using split plate 8925-1 as shown in (Fig. 202).
4. Remove 3rd gear. Install protective sleeve 8918 to output shaft and press 3rd gear off of shaft (Fig. 202).
5. Remove second gear from output shaft.
6. Remove second gear needle bearing.

Fig. 203 1st Gear, Synchro, and Bushing Removal:

7. Install output shaft to fixture 8925-3 using split plate 8925-2 (inverted) (Fig. 203).
8. Install protective sleeve 8918 to output shaft and simultaneously press off 2nd gear bushing, 1-2 synchronizer, and 1st gear (Fig. 203).

Fig. 204 Output Shaft Assembly:

9. Remove 1st gear needle bearings (2) from shaft. Inspect thrust washer (fixed to shaft) (Fig. 204).

Fig. 200 Output Shaft Section View:

Fig. 205 Output Shaft Section View:

Fig. 206 First Gear Roller Bearing:

ASSEMBLY
1. Install first gear roller bearing to shaft with smaller diameter cage ring facing outward (Fig. 206) (Fig. 205).

Fig. 207 First Gear:

2. Install first gear (Fig. 207).

Fig. 208 First Gear Roller Bearing:

3. Install other first gear roller bearing with larger diameter cage ring facing outward (Fig. 208).

Fig. 209 First Gear Friction Cone:

4. Install first gear friction cone (Fig. 209).

Fig. 210 First Gear Friction Ring:

5. Install first gear friction ring (Fig. 210). Align teeth of friction ring with notches in gear.

Fig. 211 First Gear Blocker Ring:

6. Install first gear blocker ring (Fig. 211).

Fig. 212 Install First Gear Synchronizer Hub:

Fig. 213 Synchronizer Hub/Ring Alignment:

7. Install synchronizer hub with Tool 6448A (Fig. 212). Line up blocker ring with hub as shown in (Fig. 213).

Fig. 214 Synchronizer Sleeve Orientation:

8. Install 1/2 synchronizer sleeve with groove towards first gear (Fig. 214).

Fig. 215 Synchronizer Strut:

9. Install three synchronizer strut assemblies (Fig. 215).

Fig. 216 Install Second Gear Bearing Bushing:

10. Using Tool 6448A, install second gear bearing bushing until it bottoms on synchronizer hub (Fig. 216).

Fig. 217 Second Gear Needle Bearing:

11. Install second gear needle bearing (Fig. 217).

Fig. 218 Second Gear Synchronizer Ring:

12. Install second gear blocker ring (Fig. 218).

Fig. 219 Second Gear Friction Ring:

13. Install second gear friction ring (Fig. 219).

Fig. 220 Proper Installation of Synchronizer Components:

14. Install second gear friction cone. All parts should be flush as shown in (Fig. 220).

Fig. 221 Proper Second Gear Installation:

15. Install second gear. Engage friction ring teeth with notches in gear. Components are properly installed when flush as shown in (Fig. 221)

Fig. 222 Third Gear Installation:

16. Using Tool 6448A, press third gear until it bottoms (Fig. 222).

Fig. 223 Fourth Gear Installation:

17. Using Tool 6448A, press fourth gear (collar down) until it bottoms (Fig. 223).

Fig. 224 Fifth Gear Installation:

18. Using Tool 6448A, press fifth gear (collar up) until it bottoms (Fig. 224).