Output Shaft

Fig. 12 Exploded view of mainshaft & geartrain:

Do not disassemble the 1-2, 3-4 or fifth-reverse synchros during overhaul. The synchros are serviced as an assembly. When disassembling output shaft and geartrain assembly refer to.
1. Press fifth gear and rear bearing off output shaft using standard bearing splitter tool and shop press.

Fig. 13 Reverse gear & fifth-reverse synchro removal:

2. Remove fifth-reverse snap ring and blocker ring, then two halves of fifth gear bearing from output shaft.
3. Remove reverse gear and fifth-reverse synchro assembly using flat bladed screwdriver.
4. Remove reverse gear bearing from gear or output shaft, then first gear snap ring.
5. Remove first gear, using suitable press, then first gear bearing from gear or output shaft.

Fig. 14 Removing 1-2 synchro assembly:

6. Mark position of 1-2 synchro assembly, then remove assembly from output shaft.

Fig. 15 Pilot bearing, synchro & third gear removal:

7. Remove pilot bearing, 3-4 synchro assembly, then third gear as a unit using a bearing splitter type remover tool, press tool and shop press.
8. Remove third gear bearing from gear or shaft, then second gear snap ring. Discard snap ring as it is not reuseable.
9. Remove second gear and thrust washer from shaft with suitable hydraulic press, then second gear bearing from gear or shaft.