Mainshaft

DISASSEMBLE
1. Remove first speed gear.

2. Remove snap ring in front of 3rd-4th synchronizer assembly.

3. Remove reverse driven gear.





4. Press behind 2nd speed gear to remove 3rd-4th synchronizer assembly, 3rd speed gear and 2nd speed gear along with 3rd gear bushing and thrust washer.

5. Remove 2nd speed synchronizer ring and keys.

6. Support 2nd speed synchronizer hub at front face and press mainshaft through removing 1st speed gear bushing and 2nd speed synchronizer hub.

7. Split 2nd speed gear bushing with chisel and remove bushing from shaft.

CAUTION: Exercise care not to damage mainshaft.

INSPECT
1. Wash all components in cleaning solvent.

2. Inspect mainshaft for scoring or excessive wear at thrust surfaces or splines.

3. Inspect clutch hub and clutch sleeve for excessive wear and make sure sleeve slides freely on clutch hub. Also check fit of clutch hub on
mainshaft splines.

NOTE: 3rd and 4th speed clutch sleeve should slide freely on 3rd and 4th speed clutch hub but clutch hub should be snug fit on shaft splines.

4. Inspect 3rd speed gear thrust surfaces for excessive scoring and inspect 3rd speed gear mainshaft bushing for excessive wear.

NOTE: 3rd speed gear must be a running fit on mainshaft bushing and mainshaft bushing should be a press fit on shaft.

5. Check 2nd speed thrust washer for excessive scoring.

6. Inspect 2nd speed gear for excessive wear at thrust surface. Check synchronizer springs for looseness or breakage.

7. Inspect 2nd speed gear synchronizing ring for excessive wear.

8. Inspect bronze synchronizer cone on 2nd speed gear for excessive wear or damage. Also inspect clutch gear synchronizer cone and 3rd speed gear synchronizer cone for excessive wear or damage.

NOTE: 1st and reverse sliding gear must be sliding fit on synchronizer hub and must not have excessive radial and circumferential play. If sliding gear is not free on hub, inspect for burrs which may have rolled up on front ends of half-tooth internal splines and remove by honing.

9. Inspect all gear teeth for excessive wear.







ASSEMBLE
1. Press 2nd speed bushing onto mainshaft until it bottoms against shoulder.

CAUTION: 1st, 2nd and 3rd speed gear bushings are sintered iron. Exercise care when installing.

2. Press 1st and 2nd speed synchronizer hub onto mainshaft until it bottoms against shoulder with annulus toward rear of shaft.

3. Install 1st and 2nd synchronizer keys and springs.





4. Press 1st speed gear bushing onto mainshaft until it bottoms against hub.

5. Install synchronizer blocking ring and 2nd speed gear onto mainshaft and against synchronizer hub. Index synchronizer key slots with keys in synchronizer hub.





6. Install 3rd speed gear thrust washer onto mainshaft with tang or thrust washer in slot on shaft and against 2nd speed gear bushing. Then press 3rd speed gear bushing onto mainshaft until it bottoms against thrust washer.

7. Install 3rd speed gear synchronizer blocker ring and 3rd speed gear onto mainshaft, against 3rd speed gear thrust washer.





8. Index synchronizer ring key slots with synchronizer assembly keys and drive 3rd and 4th synchronizer assembly onto mainshaft and against 3rd speed gear bushing with thrust face toward 3rd speed gear. Retain synchronizer assembly with snap ring.

9. Install reverse driver gear with fork groove toward rear.

10. Install 1st speed gear onto mainshaft and against 1st and 2nd synchronizer hub. Install 1st speed gear thrust washer.