Input Shaft

Special Tools:

Disassembly

1. Remove the (A) transmission input shaft pilot bearing, (B) bearing outer snap ring, (C) third and fourth synchronizer spacer and (D) thrust bearing.

2. Remove the (A) third/fourth synchronizer, (B) third gear synchronizer blocking ring, (C) third gear and (D) gear bearing.

3. CAUTION: Make sure that the output shaft flange does not contact or ride up onto press cradle. Improper positioning can result in component damage.

Use an (A) arbor press to remove the (B) output shaft center bearing, (C) first gear, (D) first/second synchronizer, (E) first/synchronizer blocking rings and (F) second gear.

Assembly

1. Use (A) Dial Indicator with Bracketry to check (B) output shaft runout.
- Check runout in several places along the output shaft. If runout exceeds specification, replace the shaft.

2. Identify the (A) third gear synchronizer blocking ring and (B) first, second and fourth synchronizer blocking ring.

3. Inspect the (A) synchronizer blocking rings for proper contact with (B) cone surface of gears.

4. Inspect the (A) synchronizer blocking rings for wear on (B) gear.
- If clearance is less than specification, replace ring or gear.

5. Assemble the first and second gear assembly.
1 Install the second gear needle bearing.
2 Install the second gear.
3 Install the second synchronizer blocking ring.
4 Install the first/second synchronizer with the identification hole in the sleeve facing first gear.
5 Install the first gear synchronizer blocking ring.
6 Install first gear.
7 Install the first gear needle bearing.
8 Install the input bearing spacer.
9 Position the output shaft center bearing.

6. Use (A) Pinion Bearing Replacer, (B) Remover/Replacer Tube and (C) an arbor press to press the (D) center bearing into place.

7. NOTE: Install the third/fourth synchronizer with the chamfer on the sleeve facing fourth gear.

Install the (D) third gear bearing, (C) third gear, (B) third gear synchronizer blocking ring and (A) third/forth synchronizer.

8. Install the (D) thrust bearing, (C) third and fourth synchronizer spacer, (B) bearing outer snap ring and (A) transmission input shaft pilot bearing.

9. Check the third/fourth clutch hub end play.

Bearing Outer Snap Ring Select Chart:

- If clearance is not within specification, select proper bearing outer snap ring.