Assembly

ASSEMBLY




Figure 1 Intermediate Shaft Assembly







NOTE: Do not re-use snap rings when servicing the intermediate shaft assembly. Discard snap rings and install new ones provided with available snap ring service kit.

NOTE: When installing 1/2 & 5/R synchronizers, make sure to align oil slots on synchronizer hub face with oil hold in the shaft splined hub journal.

NOTE: Refer to (Figure 1) for intermediate shaft assembly reference.

1. Press intermediate shaft into NEW roller bearing with arbor press (Figure 2).




Figure 2 Intermediate Shaft Bearing Installation






2. Install intermediate shaft roller bearing snap ring (Figure 3).




Figure 3 Intermediate Shaft Roller Bearing Snap Ring


1 - SNAP RING

3. Install 1st gear thrust bearing (Figure 4). Blue markings on bearing should face down towards output gear.




Figure 4 1st Gear Thrust Bearing Removal/Installation


1 - THRUST BEARING

4. Install 1st gear needle bearing to intermediate shaft (Figure 5).




Figure 5 1st Gear Needle Bearing


1 - 1ST GEAR NEEDLE BEARING

5. Install 1st gear to intermediate shaft (Figure 6).




Figure 6 1st Gear Installation


1 - 1ST GEAR

6. Install 1/2 synchro to fixture 8483. Insert 1st gear blocker ring, friction cone, and reactor ring as shown in (Figure 7).




Figure 7 1/2 Synchro on Fixture 8483






7. Install intermediate shaft to synchro assembly on fixture (Figure 8). When installing 1/2 synchronizer, make sure to align oil slots on synchronizer hub face with oil hole in the shaft splined hub journal. Line up friction cone and reactor ring tabs to gear slots. Remove shaft assembly from fixture.




Figure 8 Install 1/2 Synchro to Intermediate Shaft






8. Install NEW 1/2 synchro snap ring (Figure 9).




Figure 9 1/2 Synchro Snap Ring






9. Install 2nd gear blocker ring (Figure 10).




Figure 10 2nd Gear Blocker Ring


1 - 2ND GEAR BLOCKER RING

10. Install 2nd gear friction cone (Figure 11).




Figure 11 2nd Gear Friction Cone


1 - 2ND GEAR FRICTION CONE

11. Install 2nd gear reactor ring (Figure 12).




Figure 12 2nd Gear Reactor Ring


1 - 2ND GEAR REACTOR RING

12. Install 2nd gear and needle bearing to intermediate shaft (Figure 13) (Figure 14).




Figure 13 2nd Gear Removal/Installation










Figure 14 2nd Gear Needle Bearing Removal/Installation


1 - NEEDLE BEARING

13. Press 3/4 cluster gear onto intermediate shaft using cup 8481 (Figure 15).




Figure 15 Install 3/4 Cluster Gear using Tool 8481






14. Install NEW 3/4 cluster gear snap ring (Figure 16).




Figure 16 3/4 Cluster Gear Snap Ring


1 - SNAP RING

15. Install 5th gear and needle bearing to intermediate shaft (Figure 17) (Figure 18).




Figure 17 5th Gear Removal/Installation










Figure 18 5th Gear Needle Bearing Removal/Installation


1 - 5TH GEAR NEEDLE BEARING

16. Install 5th gear blocker ring to synchronizer (Figure 19).




Figure 19 5th Gear Blocker Ring to Synchro






17. Install 5th gear synchronizer assembly to intermediate shaft (Figure 20). When installing 5/R synchronizer, make sure to align oil slots on synchronizer hub face with oil hole in the shaft splined hub journal.




Figure 20 Install 5/R Synchro and 5th Blocker Ring to 5th Gear






18. Install NEW 5/R synchro snap ring (Figure 21).




Figure 21 5/R Synchro Snap Ring


1 - SNAP RING

19. Install reverse gear blocker ring (Figure 22).




Figure 22 Reverse Gear Blocker Ring






20. Install reverse gear needle bearing (Figure 23).




Figure 23 Reverse Gear Needle Bearing


1 - NEEDLE BEARING

21. Install reverse gear to intermediate shaft.
22. Install intermediate shaft sealed roller bearing and thrust washer using installer 8482 (Figure 24).




Figure 24 Sealed Roller Bearing Installation






23. Install NEW intermediate shaft sealed bearing snap ring (Figure 25).




Figure 25 Intermediate Shaft Bearing Snap Ring