Disassembly

Main Shaft








Special Tool(s)





Mainshaft-Disassembled View

Disassembly





1. NOTE: Installing a new input shaft will affect mainshaft clearance. Carry out mainshaft clearance measurement.

Remove the input shaft.





2. Using the special tools, remove and discard the input shaft bearing.
^ Install new bearings and cups in a set only. Do not install one without the other.





3. Remove and discard the input shaft rear oil dam.
^ Removing the oil dam will damage it, only remove as necessary.





4. CAUTION: To prevent damage, inspect the surface of the input shaft in the area of the bearing race to make sure it is smooth and free of burrs.

Inspect the input shaft and input shaft bearing for damage or wear.





5. CAUTION: To prevent damage, do not heat the bearing higher than 150°C (300°F).

New or original components should be heated in advance of the assembly procedure. Heating components will ease the assembly process. Place the input shaft bearing into the Gear/Bearing Heater.





6. Remove the synchronizer ring.
^ Inspect the internal surface of the synchronizer rings for a contact pattern.





7. Using the special tools, remove the input shaft pocket bearing.
^ Inspect the bearing for wear or damage. Install a new bearing as necessary. Install new bearings and cups in a set only. Do not install one without the other.

8. CAUTION: Place a cloth around the synchronizer to catch the detent springs and detents that will be released when the sliding sleeve is removed.

Remove the synchronizer sliding sleeve, detents and detent springs.





9. Remove and discard the snap ring.





10. Using the special tools, remove the synchronizer body.
^ Place the Synchronizer Remover under the third gear synchronizer ring





11. Remove the synchronizer ring.
^ Inspect the internal surface of the synchronizer rings for a contact pattern.





12. Check the clearance between the synchronizer rings and the gear.
1 Place the synchronizer ring onto the synchronizer sliding sleeve. Position the synchronizer ring on the gear.
2 Insert a feeler gauge and measure the clearance while applying pressure and rotating the synchronizer ring. The clearance should be the same around the entire circumference. Place the feeler gauge between the ring and gear clutching teeth. The ring has a raised section, inserting the feeler gauge past the teeth will give a wrong reading.
^ If the clearance is less than 1.0 mm (0.04 inch), install a new synchronizer assembly, third or fourth gear to correct to specification.





13. Remove third gear.
^ Inspect the gear for wear or damage. Install a new gear as necessary.





14. Remove mainshaft needle bearing.
^ Inspect the bearing for wear or damage. Install a new bearing as necessary.





15. Engage second gear. Position the Collet Puller and Collet Ring into the first and second synchronizer sliding sleeve.





16. CAUTION: The detent springs and detents will be released when the synchronizer sliding sleeve is lifted off the synchronizer body.

Using the special tools, remove the synchronizer sliding sleeve, the mainshaft third gear thrust washer, second gear and the mainshaft third gear bushing.
^ Inspect the gear for wear or damage. Install a new gear as necessary.





17. Remove the synchronizer ring and the mainshaft needle bearing.
^ Inspect the bearing for wear or damage. Install a new bearing as necessary.
^ Inspect the internal surface of the synchronizer rings for a contact pattern. The contact pattern should be the same on the entire internal circumference of the ring.





18. Remove and discard the snap ring.
19. Rotate the mainshaft in the Axle Bearing Seal Plate with the output end pointing upward.





20. NOTE: The snap ring is used on 4-wheel drive vehicles only.

Remove and discard the snap ring.





21. Using the special tools, remove the output shaft rear bearing.
^ Damage to the bearing can occur during removal. Inspect the bearing for wear or damage. Install a new bearing as necessary. Install new bearings and cups in a set only. Do not install one without the other.





22. Remove fifth gear.
^ Inspect the gear for wear or damage. Install a new gear as necessary.





23. Remove the fifth gear mainshaft needle bearing and the synchronizer ring.
^ The fifth gear mainshaft bearing is a split bearing.
^ Inspect the bearing for wear or damage. Install a new bearing as necessary.
^ Inspect the internal surface of the synchronizer rings for a contact pattern.





24. Remove and discard the snap ring.





25. CAUTION: The detent springs and detents will be released when the synchronizer sliding sleeve is lifted off the synchronizer body.

Remove the synchronizer sliding sleeve, the detent springs and the detents.





26. Using the special tools, remove the synchronizer body and synchronizer ring.
^ Inspect the internal surface of the synchronizer ring for a contact pattern. The contact pattern should be the same on the entire internal circumference of the ring.





27. Check the clearance between the synchronizer rings and the gear.
1 Place the synchronizer ring onto the synchronizer sliding sleeve. Position the synchronizer ring on the gear.
2 Insert a feeler gauge and measure the clearance while applying pressure and rotating the synchronizer ring. The clearance should be the same around the entire circumference. Place the feeler gauge between the ring and gear clutching teeth. The ring has a raised section, inserting the feeler gauge past the teeth will give a wrong reading.
^ If the clearance is less than 1.0 mm (0.04 inch), install a new synchronizer assembly, third or fourth gear to correct to specification.





28. Remove reverse gear.
^ Inspect the gear for wear or damage. Install a new gear as necessary.





29. Remove the mainshaft needle bearing.
^ Inspect the bearing for wear or damage. Install a new bearing as necessary.

30. Rotate the mainshaft with the input end facing upward.





31. Using the special tools, remove the synchronizer body and first gear.





32. Check the clearance between the synchronizer rings and the gear.
1 Place the synchronizer ring onto the synchronizer sliding sleeve. Position the synchronizer ring on the gear.
2 Insert a feeler gauge and measure the clearance while applying pressure and rotating the synchronizer ring. The clearance should be the same around the entire circumference. Place the feeler gauge between the ring and gear clutching teeth. The ring has a raised section, inserting the feeler gauge past the teeth will give a wrong reading.
^ If the clearance is less than 1.0 mm (0.04 inch), install a new synchronizer assembly, third or fourth gear to correct to specification.





33. Remove the mainshaft needle bearing.
^ Inspect the bearing for wear or damage. Install a new bearing as necessary.

34. CAUTION: To prevent damage, do not heat the rear mainshaft bearing, the output bearing thrust washer and the mainshaft low gear bushing higher than 150'C (300'F) maximum.

New or original components should be heated in advance of the assembly procedure. Heating will case the assembly process. Place the input shaft pocket bearing, the synchronizer bodies, the mainshaft third gear thrust washer, the mainshaft third gear bushing and the output shaft rear bearing into the Gear/Bearing Heater. Allow 45 minutes for components to reach 150°C (300°F).