Main Shaft

Special Tools:

Disassembly

1. NOTE: Use brass pads in the vice jaws to prevent damage to the main shaft.

Position the main shaft assembly in a vice.

2. Remove the synchronizer ring.

3. Remove the input shaft pocket bearing.
1 Position the bearing collets on the input shaft pocket bearing.
2 Position the Remover Tube in the collets.
3 Pass the collet sleeve over the Remover Tube and into the collets.
^ Install the Forcing Screw into the remover tube.
^ Remove the input shaft pocket bearing.

4. CAUTION: Place a cloth around the synchronizer to catch the compression springs and pressure pieces that will be released when the sliding sleeves are removed.

Remove the 3rd-4th gear sliding sleeve.

5. Remove the snap ring.

6. Remove the synchronizer body.
^ Position the collets and collet ring.
^ Position the 2-jaw puller.
^ Remove the synchronizer body.

7. Remove the synchronizer ring.

8. Remove the 3rd gear and the needle bearings.
9. Lift the 1st-2nd synchronizer ring up as far as it will go.

10. Position the Collets and the Collet Ring so they seat in the groove in the synchronizer ring.

11. CAUTION: Position a cloth around the 1st-2nd synchronizer to catch the springs and pressure pieces that will be released when the sliding sleeve (part of synchronizer) clears the 1st-2nd synchronizer.

Position the collets and collet ring in a press. Position the Shaft Protector on the main shaft.
12. Remove 1st-2nd synchronizer ring, 2nd gear, and the 3rd gear bearing spacer.

13. Remove the 1st-2nd synchronizer snap ring.
14. Reposition the main shaft in the vice so that the output end is facing up.

15. CAUTION: Failure to use a bearing puller will destroy the output shaft rear bearing.

Remove the output shaft rear bearing.
^ On 4-wheel drive vehicles, remove the snap ring.
^ Position the Bearing Pulling Attachment so that it will pull against the shoulder at the tapered rollers, not the bearing cage.
^ Position the Push-Puller Set on the Bearing Pulling Attachment.
^ Remove the output shaft rear bearing.

16. Remove the 5th gear and 5th gear needle bearing.

17. Remove the synchronizer ring.

18. Remove the snap ring.

19. CAUTION: Position a cloth around the 5th-reverse synchronizer to catch the springs and pressure pieces that will be released when the sliding sleeve clears the 5th-reverse synchronizer.

Remove the 5th-reverse sliding sleeve.

20. Remove the 5th-reverse synchronizer hub.
^ Position the Bearing Pulling Attachment between 1st gear and the synchronizer hub.
^ Position the push-puller on the Bearing Pulling Attachment in a press.
^ Remove the 5th-reverse synchronizer hub.

21. Remove the synchronizer ring from the reverse gear.

22. Remove the reverse gear and needle bearings.

23. NOTE: There is an alternate method for this procedure; refer to Step 24.

Remove the main shaft from the vice and position in a press. Remove the 1st gear, 1st gear needle bearings and the 1st-2nd gear synchronizer.

24. An alternate method is to position the main shaft in a vice.
^ Position a Bearing Pulling Attachment on first gear.
^ Attach the Push-Puller to the pulling attachment.
^ Remove 1st gear, the 1st/2nd gear synchronizer and the 1st gear needle bearings.

Assembly

1. NOTE: Use brass pads or equivalent in the vice jaws to prevent damage to the main shaft.

Position the main shaft in a vice.

2. Install the reverse gear bearing and the reverse gear. The clutching teeth must face upward.

3. CAUTION: To prevent damage before installing the original synchronizer, check for excessive wear.

Position the reverse gear synchronizer ring on the reverse gear.

4. CAUTION: To prevent damage, do not heat synchronizer body for more than 15 minutes.

Install the 5th/reverse synchronizer hub.
^ Use a gear/bearing heater or a heat gun to heat the synchronizer hub to 160°C (320°F).
^ Position the synchronizer hub on the main shaft so that the side with the deeper hub faces down and the short lugs on the synchronizer ring engage the shallow gaps in the synchronizer hub.

5. Install the snap ring.
^ Check the reverse gear end play. End play is 0.15 - 0.35 mm (0.00591 - 0.01378 inch).
^ If end play is not within specification, replace the snap ring.

6. Install the synchronizer sliding sleeve with the two grooves facing up. Position the sliding sleeve over the synchronizer hub in three positions on the sliding sleeve. Three teeth have been cut away. Align these areas with the shallow gaps in the synchronizer hub and the three lugs on the synchronizer ring. Slide the sliding sleeve down to engage the clutching teeth of the reverse gear.

7. CAUTION: To prevent damage, if the original springs are not being replaced, inspect them before reuse.

Install the pressure pieces and springs.
1 Measure the springs. The minimum unloaded length is 148 mm (0.538 inch) and the diameter is 5.960 mm (0.235 inch). Replace the springs that are not within specification.
2 Insert the three compression springs and pressure pieces in the recesses in the synchronizer hub.

8. Position the short lugs on the synchronizer ring over the shallow gaps in the synchronizer hub. Install the synchronizer ring on the synchronizer hub.

9. Slide the sliding sleeve upward while pushing down on the synchronizer ring.

10. Install the 5th gear needle bearings and 5th gear.

11. CAUTION: Do not heat the output shaft rear bearing for more than 15 minutes.

CAUTION: If necessary to drive the output shaft rear bearing on, drive against the inner race only. Do not drive against the bearing cone.

Install the output shaft rear bearing.
^ Use a Gear/Bearing Heater or Heat Gun to heat the inner race of the output shaft rear bearing to 160°C (320°F).
^ Install the bearing on the main shaft until it seats against its stop.

12. On 4-wheel drive vehicles, install the snap ring.
13. On 4-wheel drive vehicles, check the 5th gear end play. End play must be 0.15 - 0.35 mm (0.006 - 0.014 inch).
14. Reposition the mainshaft in the vice and clamp it at the output end.

15. Install the 1st gear needle bearings and the 1st gear.

16. Install the synchronizer ring on 1st gear.

17. CAUTION: Do not heat the synchronizer body for more than 15 minutes.

Install the 1st/2nd synchronizer hub.
^ Use a Gear/Bearing Heater to heat the 1st/2nd synchronizer to 160°C (320°F).
^ Position the synchronizer hub on the mainshaft so that the short lugs on the synchronizer ring engage the shallow gaps in the synchronizer hub.
^ Lightly tap the synchronizer hub down until it stops against the synchronizer ring. The word ENGINE will be visible when the synchronizer hub is properly installed.

18. Install the snap ring. Check the clearance between the snap ring and the synchronizer hub. Clearance should not be more than 0.1 mm (0.004 inch).
19. Check the first gear end play. End play should be 0.15 - 0.35 mm (0.006 - 0.014 inch).

20. Install the sliding sleeve with the tapered collar facing down. Position the sliding sleeve over the synchronizer hub. In three positions on the sliding sleeve three teeth have been cut away; align these areas with the shallow gaps in the synchronizer hub and the three lugs on the synchronizer ring. Slide the sliding sleeve down until it rests against the first gear.

21. CAUTION: If the original springs are not being replaced, inspect them before reuse.

Install the compression springs and pressure pieces.
^ Measure the springs. The minimum unloaded length is 14.8 mm (0.583 inch) and the diameter is 0.95 mm (0.037 inch). Replace the springs that are not within specifications.
^ Insert the compression springs with the pressure pieces in the recesses in the synchronizer hub.

22. Install the 2nd gear synchronizer ring.
^ Position the short lugs on the synchronizer ring over the gaps in the synchronizer hub.
^ Place the synchronizer ring on the synchronizer hub.
^ While pushing down on the synchronizer ring, move the sliding sleeve to the center position.

23. Install the 2nd speed gear.
^ Install the 2nd speed gear needle bearings.
^ Install the 2nd speed gear.

24. CAUTION: To prevent damage, do not heat the thrust washer for more than 15 minutes.

Install the 3rd speed thrust washer.
^ Use a Gear/Bearing Heater or Heat Gun to heat the thrust washer to 160°C (320°F).
^ Position the thrust washer on the mainshaft.
^ Tap the thrust washer down until it seats against the stop on the mainshaft.

25. CAUTION: Do not heat the input bearing pacer for more than 15 minutes.

Install the 3rd gear bearing spacer.
^ Use a Gear/Bearing Heater or Heat Gun to heat the 3rd speed bearing spacer to 160°C (320°F).
^ Position the 3rd speed spacer on the mainshaft.
^ Tap the spacer down until it seats against its stop.

26. Check the 2nd gear end play. End play is between 0.15 - 0.45 mm (0.006 - 0.017 inch).

27. Allow the 3rd speed spacer to completely cool.
28. Install the 3rd gear bearing and 3rd gear.

29. Install the synchronizer ring.

30. CAUTION: Do not heat the synchronizer for more than 15 minutes.

Install the 3rd/4th gear synchronizer hub.
^ Use a Gear/Bearing Heater or Heat Gun to heat the synchronizer hub to 160°C (320°F).
^ Position the synchronizer hub so that the short lugs on the synchronizer ring engage in the shallow gaps in the synchronizer hub.
^ Install the synchronizer hub with the recess in the synchronizer hub facing up.

31. Install a new snap ring.
32. Check the clearance between the snap ring and the synchronizer. Maximum clearance is 0.1 mm (0.004 inch).
33. Check the 3rd gear end play. End play should be 0.15 - 0.35 mm (0.00591 - 0.01378 inch).
34. Position the sliding sleeve with the smaller of the two grooves facing down. In three positions on the sliding sleeve three teeth have been cut away. Align these areas with the shallow gaps in the synchronizer hub and the three lugs on the synchronizer ring. Slide the sliding sleeve down until it rests against 3rd gear.

35. CAUTION: If the original springs are not being replaced, inspect them before reuse.

Install the compression springs and pressure pieces.
^ Measure the springs. The minimum unloaded length is 14.8 mm (0.583 inch) and the diameter is 0.95 mm (0.037 inch). Replace the springs that are not within specifications.
^ Insert the springs and pressure pieces in the recesses in the synchronizer.

36. Install the 4th gear synchronizer ring.
^ Position the synchronizer ring over the shallow gaps in the synchronizer hub.
^ Place the synchronizer ring on the synchronizer hub.
^ While pushing down on the synchronizer ring, move the sliding sleeve to the center position.

37. CAUTION: Do not heat the input shaft pocket bearing for more than 15 minutes.

CAUTION: If necessary to drive the input shaft pocket bearing on, drive against the inner race only. Do not drive against the bearing cone.

NOTE: An alternate method of installation is to use an inner pinion bearing cone replacer and a press.

Install the input shaft pocket bearing.
^ Use a Gear/Bearing Heater to heat the inner race of the input shaft pocket bearing to 160°C (320°F).
^ Position the input shaft pocket bearing on the main shaft.
^ Drive the bearing on the main shaft until it seats against its stop.