Main Shaft

Exploded View Main Shaft Assembly:

DISASSEMBLY AND REASSEMBLY

1. After removal from the transmission case, disassemble the main shaft and inspect for synchronizer, main shaft and bearing wear.
a. Clearance between synchronizer and synchronizer hub.
b. Check main shaft for wear at bearing surfaces and straightness.
c. Check bearings for discolored surfaces, flaking chrome, and roughness when spining.
d. Check gears for wear and Sharp edges on teeth.

Exploded View Main Shaft Assembly:

2. Installation of ball bearing inner race second speed gear. Holding second speed gear on press bed, using suitable tool, push rear end of main shaft to remove bearing inner race (double bearing only), gear bearing sleeve, first speed gear, 1-2 speed synchronizer and second speed gear.

Synchronizer Ring Inspection:

3. Check synchronizer ring for worn and damaged internal threads. With synchronizer assembled to cone of each gear check dimension "A". If it exceeds the limit, replace the synchronizer ring and or gear.

LIMIT: 0.020 in (0.5 mm).

Mating Synchronizer Sleeve And Hub:

3-4 Synchronizer Hub:

Synchronizer Keys:

4. Assembly of 3-4 synchronizer sleeve, 3-4 speed synchronizer hub, synchronizer key and synchronizer spring.
a. Mate synchronizer hub with sleeve. Make sure that hub and sleeve slide smoothly. If they do not, replace hub and sleeve assembly.
b. The 3-4 synchronizer sleeve has teeth missing at six positions. Assemble hub to sleeve in such a way that center tooth "T" between two missing teeth will touch synchronizer key.
c. Carefully install 3-4 synchronizer hub since only 3-4 synchronizer is directional Smaller diameter side "A" of center boss is front of 3-4 synchronizer hub.
d. Insert the three key assembly into grooves of synchronizer hub.
e. Install two synchronizer springs to synchronizer. When synchronizer springs are installed, make sure that front and rear ones are not faced in same direction.

3-4 synchronizer Hub Assembly:

5. Installation of 3-4 synchronizer hub and snap ring.
a. Assemble the 3-4 synchronizer positioning hub toward the step on the main shaft.
b. Install the main shaft front end snap ring. This snap ring is selective in thickness. Choose a snap ring that will allow minimum clearance between the snap ring and hub.
c. Make sure that 3rd speed gear turns smoothly.
6. Assemble the 1-2 synchronizer by the same procedure as for the 3-4 synchronizer in the previous step.