Output Shaft

Output Shaft





Special Tool(s)

Disassembly





1. Remove the following components:
1 The bearing outer snap ring.
2 The 3rd/4th synchronizer spacer.
3 The thrust washer.





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





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

Position the output shaft in a press. Press off the output shaft center bearing, the 1st gear, the 1st/2nd synchronizer assembly and the 2nd 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 shaft.





2. Identify the synchronizer blocking ring:
1 3rd gear synchronizer blocking ring.
2 1st, 2nd and 4th synchronizer blocking ring.





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





4. Inspect the synchronizer blocking rings for wear on the gear.
^ If the clearance is less than specification, install a new ring or gear.





5. Assemble the 1st and 2nd gear assembly as follows:
1 Install the 2nd gear needle bearing.
2 Install the 2nd gear.
3 Install the 2nd synchronizer blocking ring. Vehicles equipped with a dual cone blocking ring.
4 Install the 1st/2nd synchronizer. The identification hole in the sleeve must face 1st gear.
5 Install the 1st gear synchronizer blocking ring.
6 Install the 1st gear.
7 Install the 1st gear needle bearing.
8 Install the input bearing spacer.
9 Position the output shaft center bearing.





6. Using the special tools and a press, press the center bearing into place.





7. NOTE: Install the 3rd/4th synchronizer with the chamfer on the sleeve facing 4th gear.

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





8. Install the following components:
1 The thrust washer.
2 The 3rd/4th synchronizer spacer.
3 The bearing outer snap ring.





9. Check the 3rd/4th clutch hub end play.
^ If the clearance is not within specification, select the correct bearing outer snap ring.
^ Bearing outer snap ring selection:
- 1.50 mm (0.0590 inch)
- 1.55 mm (0.0610 inch)
- 1.60 mm (0.0629 inch)
- 1.65 mm (0.0649 inch)
- 1.70 mm (0.0669 inch)
- 1.75 mm (0.0688 inch)
- 1.80 mm (0.0708 inch)
- 1.85 mm (0.0728 inch)
- 1.90 mm (0.0748 inch)
- 1.95 mm (0.0767 inch)