Output Shaft

1. Place second gear on bench with the synchro clutch ring up.

Fig. 67:

2. Install the second gear synchro inner blocker ring onto second gear.

Fig. 68:

3. Install the second gear synchro friction cone over the blocker ring and onto second gear.

NOTE: The area between the locating tabs on the friction cone alternate between being high and low areas. The area between the locating tab recesses on the second gear clutch ring have matching high and low areas. Ensure that the high area between the locating tabs on the friction cone are located to the low areas between the recesses on clutch ring.

Fig. 69:

4. Install the second gear synchro outer blocker ring over the second gear synchro friction cone. Align one of the lugs on the outer ring with a lug on the inner ring.

Fig. 70:

5. Install the 1-2 synchro assembly onto the second gear assembly.
6. Reverse the assembly on the bench.

Fig. 71:

7. Install second gear bearing into second gear.
8. Move the completed 1-2 synchro, second gear, and second gear bearing to a suitable shop press with second gear facing upward.

Fig. 72:

9. Install the output shaft into the second gear/1-2 synchro assembly with the front of the output shaft facing upward.
10. Press the output shaft into position.
11. Place first gear on bench with the synchro clutch ring up.
12. Install the first gear synchro inner blocker ring onto first gear.
13. Install the first gear synchro friction cone over the blocker ring and onto first gear.

NOTE: The area between the locating tabs on the friction cone alternate between being high and low areas. The area between the locating tab recesses on the first gear clutch ring have matching high and low areas. Ensure that the high area between the locating tabs on the friction cone are located to the low areas between the recesses on clutch ring.

14. Install the first gear synchro outer blocker ring over the first gear synchro friction cone. Align one of the lugs on the outer ring with a lug on the inner ring.
15. Reverse the output shaft in the press.
16. Install the first gear bearing sleeve onto the output shaft.

Fig. 73:

17. Install the first gear bearing sleeve the remainder of the way onto the output shaft using Installer 8228 and a shop press.

Fig. 74:

18. Install the first gear and blocker assembly onto the output shaft.
19. Install the first gear bearing over the output shaft and into first gear.

Fig. 75:

20. Install the output shaft thrust washer onto the output shaft.

Fig. 76:

21. Install the rear output shaft bearing onto the output shaft using Installer 8228 and a shop press.
22. Install a new snap-ring to hold the rear output bearing onto the output shaft. The snap-ring is selectable. Install the thickest snap-ring which will fit into the groove.
23. Reverse the output shaft in the Fixture 8227 and support the shaft with press blocks under first gear.
24. Install the sixth gear bearing onto the output shaft.

Fig. 77:

25. Install the sixth gear onto the output shaft and over the sixth gear bearing.
26. Install the sixth gear friction cone onto sixth gear.

NOTE: The alignment of the high and low areas on the remaining friction cones to the matching clutch rings differs from the first two.

NOTE: The area between the locating tabs on the friction cone alternate between being high and low areas. The area between the locating tab recesses on the sixth gear clutch ring have matching high and low areas. Ensure that the high area between the locating tabs on the friction cone are located to the high areas between the recesses on clutch ring.

Fig. 78:

27. Install the sixth gear blocker ring over the sixth gear friction cone.

Fig. 79:

28. Install Guide 8235 onto the end of the output shaft.

Fig. 80:

29. Install the 5 6 synchro over Guide 8235 and onto the output shaft.
30. Press the 5-6 synchro onto the output shaft using Installer 8156 and a shop press.