Intermediate Shaft

Fig. 9 Exploded view of intermediate shaft:

1. Remove intermediate shaft rear bearing snap ring, then using suitable puller, remove rear bearing and 4th speed gear.
2. Remove 3-4 synchronizer hub snap ring, then using suitable puller, remove 3-4 synchronizer hub and 3rd speed gear.
3. Remove snap ring, then the split thrust washer. During installation, snap ring opening must be positioned 90° away from thrust washer openings.
4. Lift off 2nd speed gear and stop ring, then remove 1-2 synchronizer hub snap ring, synchronizer assembly and 1st speed gear.
5. Remove 1st speed gear thrust washer and anti-spin pin. During installation, thrust washer chamfered edge must face towards pinion gear.

Fig. 10 1-2 & 3-4 synchronizers:

Fig. 11 5th gear synchronizer:

Fig. 12 Assembled synchronizer:

6. Disassemble synchronizers. Inspect synchronizers and replace as necessary.
7. Reverse procedure to assemble.