Output Shaft and Bearing

Output Shaft and Bearing

Special Tools:

Special Tool(s)

Disassembly

1. Remove the following components:
1 The bearing outer snap ring.
2 The third/fourth synchronizer spacer.
3 The thrust washer.

2. Remove the following components:
1 The third/fourth synchronizer.
2 The third gear blocking ring.
3 The third gear.
4 The third gear needle bearing.

3. CAUTION: Make sure that the output shaft flange does not contact or ride up onto the press cradle. Incorrect positioning can result in component damage. Position the output shaft in a press. Press off the output shaft center bearing, the first gear, the first/second synchronizer assembly and the second gear.

Assembly

1. Using the special tool, check the output shaft runout.
- Check runout in several places along the output shaft. If runout exceeds specification, install a new output shaft.

2. Identify the synchronizer blocking ring.
1 First gear synchronizer blocking ring (R1 model)
2 Third gear synchronizer blocking ring (R1 and R1 HD models)
3 First gear synchronizer blocking ring (R1 HD model)
4 Second and fourth gear synchronizer ring (R1 and R1 HD models)

3. Inspect the synchronizer blocking rings for correct contact with the cone surface of first gear.

4. Inspect the synchronizer blocking rings for wear on second gear.
- Vehicles equipped with 2.3L and 3.0L engines have dual cone blocking rings. Measure both blocking rings.
- If clearance is less than specification, install a new blocking ring or gear.

5. Assemble the first and second gear assembly as follows.
1 Install the second gear needle bearing.
2 Install the second gear.
3 Install the second synchronizer blocking ring.
- Vehicles equipped with 2.3L and 3.0L engines have a dual cone blocking ring.
4 Install the first/second synchronizer. The identification hole in the sleeve must face first gear.
5 Install the first gear synchronizer blocking ring.
6 Install the first gear.
7 Install the first gear needle bearing.
8 Install the input bearing spacer.
9 Position the output shaft center bearing.

6. Using the special tools, press the output shaft center bearing into place.

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

Install the following components:
1 The third gear needle bearing.
2 The third gear.
3 The third gear blocking ring.
4 The third/fourth synchronizer.

8. Install the following components:
1 The thrust washer.
2 The third/fourth synchronizer spacer.
3 The bearing outer snap ring.

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

Bearing Outer Snap Ring Select Chart