Output Shaft Assembly

1. Lubricate shaft, gears and bearings with recommended lubricant during assembly. Petroleum jelly can be used to hold parts in place.
2. Check bearing surfaces of output shaft for nicks or scratches. Smooth surfaces with 320/400 grit emery cloth if necessary. Apply oil to emery cloth and shaft surface before polishing.
3. Inspect and replace any synchro ring that exhibits wear or damage. Completely immerse each synchro ring in lubricant before installation.

Fig. 53:

4. Lubricate and install reverse gear needle bearing on shaft (Fig. 53). Slide bearing up against shoulder on output shaft.

Fig. 54:

5. Install reverse gear over needle bearing (Fig. 54).

Fig. 55:

6. Install solid brass synchro ring on reverse gear (Fig. 55).
7. Assemble fifth-reverse synchro hub, sleeve, struts, springs and detent balls, if not previously done.

CAUTION: The fifth-reverse synchro hub and sleeve can be installed backwards if care is not exercised. One side of the hub has shoulders around the hub bore. Make sure this side of the hub is facing the front of the shaft. In addition, one side of the sleeve is tapered. Be sure the sleeve is installed so the tapered side will be facing the front of the shaft.

Fig. 56:

8. Start fifth-reverse synchro assembly on output shaft splines by hand. Then seat synchro onto shaft with shop press and Remover 6310-1 (Fig. 56).

Fig. 57:

9. Install new fifth-reverse hub snap ring (Fig. 57) as follows:
a. Snap rings are available in thicknesses from 2.00 mm to 2.20 mm (0.078 to 0.086 inch).
b. Install thickest snap ring that will fit in shaft groove.
c. Verify that snap ring is completely seated in groove before proceeding.

Fig. 58:

10. Install fifth gear synchro ring in synchro, hub and sleeve (Fig. 58).

Fig. 59:

11. Install fifth gear bearing. Spread bearing only enough to clear shoulder on output shaft (Fig. 59). Be sure bearing is properly seated after installation.

Fig. 60:

12. Install fifth gear on shaft and onto bearing (Fig. 60).

Fig. 61:

13. Invert output shaft and set the shaft in Remover 6310-1 so that fifth gear is seated on the tool (Fig. 61).
14. Install first gear bearing on output shaft (Fig. 61). Be sure bearing is seated on shaft shoulder and is properly joined.
15. Install the first gear inner blocker ring onto first gear.

Fig. 62:

16. Install first gear on shaft and over bearing (Fig. 62).
17. Install the first gear friction cone over the inner blocker ring.

Fig. 63:

18. Install first gear synchro/outer blocker ring (Fig. 63) (Fig. 63) over the first gear friction cone.
19. Assemble 1-2 synchro hub sleeve, springs, struts and detent balls.

CAUTION: The 1-2 synchro hub and sleeve can be installed backwards if care is not exercised. One side of the synchro sleeve is marked First Gear Side. Be sure this side of the sleeve will face first gear after installation.

Fig. 64:

20. Start 1-2 synchro assembly on shaft by hand (Fig. 64). Be sure synchro sleeve is properly positioned. Side marked first side must be facing first gear.

Fig. 65:

21. Press 1-2 synchro onto output shaft using suitable size pipe tool and shop press (Fig. 65).

CAUTION: Take time to align the synchro ring and sleeve as hub the is being pressed onto the shaft. The synchro ring can be cracked if it becomes misaligned.

22. Install interim ring.

Fig. 66:

23. Install new 1-2 synchro hub snap ring (Fig. 66) as follows:
a. Snap rings are available in thicknesses from 1.80 mm to 2.00 mm (0.070 to 0.078 inch).
b. Install thickest snap ring that will fit in shaft groove.
c. Verify that snap ring is completely seated in groove before proceeding.

Fig. 67:

24. Install second gear synchro/outer blocker ring in 1-2 synchro hub and sleeve (Fig. 67). Be sure synchro ring is properly seated in sleeve.
25. Install the second gear friction cone into the second gear synchro/outer blocker ring.
26. Install the second gear inner blocker ring into the friction cone.

Fig. 68:

27. Install second gear needle bearing on shaft (Fig. 68).

Fig. 69:

28. Install second gear onto shaft and bearing (Fig. 69). Make sure that second gear is fully seated on synchro components.

Fig. 70:

29. Install two-piece thrust washer (Fig. 70). Be sure washer halves are seated in shaft groove and that washer lugs are seated in shaft lug bores. Also, ensure that the I.D. grooves and markings noted during removal are facing the correct direction. The diamond shaped marks on the face of the washer must face the front of the shaft.

Fig. 71:

30. Start retaining ring around two-piece thrust washer (Fig. 71). Make sure that the locating dimple is between the thrust washer halves.

Fig. 72:

31. Seat thrust washer retaining ring with plastic mallet (Fig. 72).

Fig. 73:

32. Install third gear needle bearing on shaft (Fig. 73).

Fig. 74:

33. Install third gear on shaft and bearing (Fig. 74).

Fig. 75:

34. Install third speed synchro ring on third gear (Fig. 75).
35. Assemble 3-4 synchro hub, sleeve, springs, struts and detent balls.

CAUTION: The 3-4 synchro hub and sleeve can be installed backwards if care is not exercised. One side of the sleeve has grooves in it. Be sure this side of sleeve is also facing the front of the shaft.

Fig. 76:

36. Start 3-4 synchro hub on output shaft splines by hand (Fig. 76).

Fig. 77:

37. Press 3-4 synchro assembly onto output shaft with shop press and suitable size pipe tool (Fig. 77). Make sure that the tool presses on hub as close to output shaft as possible but does not contact the shaft splines.

Fig. 78:

38. Install 3-4 synchro hub snap ring (Fig. 78) as follows:
a. Snap rings are available in thicknesses from 2.00 mm to 2.30 mm (0.078 to 0.090 inch).
b. Install thickest snap ring that will fit in shaft groove. Use heavy duty snap ring pliers to install new ring.
c. Verify that snap ring is completely seated in groove before proceeding.
39. Install output shaft bearing.

Fig. 79:

40. Install output shaft bearing snap ring (Fig. 79). Use heavy duty snap ring pliers and spread snap ring only enough to install it. Be sure snap ring is completely seated in shaft groove before proceeding.

Fig. 80:

41. Verify correct position of synchro sleeves before proceeding with assembly operations (Fig. 80). Grooved side of 3-4 sleeve should be facing forward. First gear side of 1-2 sleeve should be facing first gear. Tapered side of fifth-reverse sleeve should be facing forward.