Output Shaft and Bearing

Special Tools:

Disassembly

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

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

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

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

Assembly

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

2. Identify the synchronizer blocking ring.
1 Brass third gear synchronizer blocking ring.
2 Brass first and fourth gear synchronizer blocking ring.
3 Carbon second gear synchronizer blocking nag.

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

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

5. Assemble the first and second gear assembly.
1 Install the second gear needle bearing.
2 Install the Second Gear (2GR).
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 the First Gear (1GR).
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 Cone Replacer, (B) Bearing Cone Replacer, Axle Bearing/Seal Plate and an (C) 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, the (C) Third Gear (3GR), the (B) third gear synchronizer blocking ring, and the (A) third/fourth synchronizer.

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

9. Check the third/fourth clutch hub end play.
- If clearance is not within specification, select the proper bearing outer snap ring.

Bearing Outer Snap Ring Select Chart