Input Shaft: Service and Repair
DISASSEMBLE1. Press off bearing cone from fourth gear end using shaft protector tool No. D80L-625-4 and bearing pulling attachment tool No. D84L-1123-A, or equivalents.
Exploded View Of Input Shaft:
2. Remove fourth gear, synchronizer ring, and retaining ring.
3. Press off clutch hub assembly and synchronizer ring, then the third gear using shaft protector tool No. D80L-625-4 and puller plate tool No. T71P-4621-B, or equivalents.
4. Press off bearing cone from third gear end using shaft protector tool No. D80L-625-A and bearing pulling attachment tool No. D84L-1123-A, or equivalents.
ASSEMBLE
1. Install clutch hub into clutch hub sleeve, then the synchronizer keys and springs.
2. Press bearing cone onto third gear end using shaft protector tool No. D80L-625-6, bearing cone replacer tool No. T88C-7025-DH, and bearing cone installing plate tool No. T75L-1165-B, or equivalents.
NOTE: Whenever a bearing cone is removed, it must be replaced.
3. Press third gear, synchronizer ring and clutch hub assembly on shaft using shaft protector tool No. D80L-625-6, bearing installing plate tool No. T75L-1165-B, and bearing cone replacer tool No. T87C-7700O-D, or equivalents.
Synchronizer Ring Groove And Key Alignment:
NOTE: When installing synchronizer ring and clutch hub assembly, align synchronizer ring groove and synchronizer key. Ensure clutch hub assembly ridge is facing third gear.
4. Install retaining ring, synchronizer ring, fourth gear and bearing cone using shaft protector tool No. D8OL-625-6, bearing cone installing plate tool No. T75L-1 165-B and bearing cone replacer tool No. T88C-7025-DH, or equivalents.