Disassembly

DISASSEMBLY

CAUTION: Do not re-use snap rings when servicing the intermediate shaft assembly. Discard upon disassembly and install new ones provided with available snap ring service kit.

1. Install intermediate shaft assembly to arbor press table with bearing splitter P-334 under the reverse gear.
2. Install 8486-4 button to intermediate shaft. Using arbor press ram, press reverse gear and intermediate roller bearing off of shaft, while holding remaining assembly with hand (Figure 1).




Figure 1 Bearing and Reverse Gear Removal






3. Remove reverse gear blocker ring.
4. Remove reverse gear needle bearing (Figure 2).




Figure 2 Reverse Gear Needle Bearing


1 - NEEDLE BEARING

5. Remove 5/R synchro snap ring (Figure 3).




Figure 3 5/R Synchro Snap Ring


1 - SNAP RING

6. Remove 5/R synchro (Figure 4).




Figure 4 5/R Synchronizer


1 - 5/R SYNCHRO ASSEMBLY

7. Remove 5th gear blocker ring (Figure 5).




Figure 5 5th Gear Blocker Ring


1 - 5th GEAR BLOCKER RING

8. Remove 5th gear and needle bearing (Figure 6) (Figure 7).




Figure 6 5th Gear Removal/Installation










Figure 7 5th Gear Needle Bearing Removal/Installation


1 - 5TH GEAR NEEDLE BEARING

9. Remove 3/4 cluster gear snap ring (Figure 8).




Figure 8 3/4 Cluster Gear Snap Ring


1 - SNAP RING

10. Install shaft assembly into fixture 8483, with split collar 8483-3 oriented chamfer side up (Figure 9). Place 8483-2 into position with chamfer side up (Figure 10).




Figure 9 Fixture 8483










Figure 10 Loading Intermediate Shaft






11. Using an arbor press, press intermediate shaft out of 3/4 cluster gear (Figure 11).




Figure 11 Press Intermediate Shaft Out of 3/4 Cluster Gear






12. Remove intermediate shaft from fixture and remove 3/4 cluster gear from shaft (Figure 12).




Figure 12 3/4 Cluster Gear






13. Remove 2nd gear and needle bearing (Figure 13) (Figure 14).




Figure 13 2nd Gear Removal/Installation










Figure 14 2nd Gear Needle Bearing Removal/Installation


1 - NEEDLE BEARING

14. Remove 2nd gear reactor ring (Figure 15).




Figure 15 2nd Gear Reactor Ring


1 - 2ND GEAR REACTOR RING

15. Remove 2nd gear friction cone (Figure 16).




Figure 16 2nd Gear Friction Cone


1 - 2ND GEAR FRICTION CONE

16. Remove 2nd Gear outer blocker ring (Figure 17).




Figure 17 2nd Gear Outer Blocker Ring


1 - 2ND GEAR BLOCKER RING

17. Remove 1/2 synchro snap ring (Figure 18).




Figure 18 1/2 Synchro Snap Ring






18. Remove 1/2 synchro from shaft (Figure 19).




Figure 19 1/2 Synchronizer


1 - 1/2 SYNCHRONIZER

19. Remove 1st gear blocker ring (Figure 20).




Figure 20 1st Gear Blocker Ring


1 - 1ST GEAR BLOCKER RING

20. Remove 1st gear friction cone (Figure 21).




Figure 21 1st Gear Friction Cone


1 - 1ST GEAR FRICTION CONE

21. Remove 1st gear reactor ring (Figure 22).




Figure 22 1st Gear Reactor Ring


1 - 1ST GEAR REACTOR RING

22. Remove 1st gear from shaft (Figure 23).




Figure 23 1st Gear Removal


1 - 1ST GEAR

23. Remove 1st gear needle bearing (Figure 24).




Figure 24 1st Gear Needle Bearing


1 - 1ST GEAR NEEDLE BEARING

24. Remove first gear thrust bearing (Figure 25).




Figure 25 1st Gear Thrust Bearing Removal/Installation


1 - THRUST BEARING

25. Remove intermediate shaft roller bearing snap ring (Figure 26).




Figure 26 Intermediate Shaft Roller Bearing Snap Ring


1 - SNAP RING

26. Press intermediate shaft out of roller bearing supported by bearing splitter P-334 (Figure 27). Roller bearing is not re-usable once removed. It is necessary to install a new roller bearing upon re-assembly.




Figure 27 Intermediate Shaft Roller Bearing Removal