Mainshaft

Disassembly

Fig. 8 Removing Reverse Speed Gear:

1. Remove clutch gear and synchronizer ring.
2. Attach two-jaw puller to clutch gear, then remove synchronizer assembly and third speed gear together.
3. Remove synchronizer ring, clutch gear, bearing, spacer, retaining ring, thrust washer, retaining pin, second speed gear, bearing, retaining ring and synchronizer rings.
4. Remove square cut synchronizer spring from synchronizer hub, then retaining ring.
5. Remove synchronizer assembly. Do not let synchronizer assembly come apart.
6. Remove synchronizer rings and retaining ring.
7. Press mainshaft through reverse gear, thrust washer, bearing, overdrive gear and rotor, if equipped. Do not let mainshaft fall to floor, Fig. 8.
8. Remove retaining pin, bearing, spacer, sleeve and retaining ring.
9. Remove mainshaft synchronizer reverse gear.
10. Remove first speed gear and bearing.
11. Clean all parts in suitable solvent.


Inspection
1. Inspect gears for cracks, chipped gear teeth and other damage that could cause gear noise.
2. Inspect thrust washers for damage or wear.
3. Inspect synchronizer sleeves for a sliding fit on synchronizer hubs, also, hubs have to be snug fit on mainshaft splines.
4. Inspect synchronizer springs and keys for looseness and damage.
5. Inspect all gear teeth for excessive wear.
6. Inspect bearings and bearing surfaces for nicks, burrs and wear.
7. Lubricate all roller bearings with light engine oil and check for rough rotation.


Assembly

Fig. 9 Installing Reverse Speed Gear:

1. Install bearing and first speed gear.
2. Install mainshaft synchronizer reverse gear.
3. Install retaining ring, sleeve, spacer, bearing and retaining pin.
4. Install reverse gear, thrust washer, bearing, overdrive gear and rotor, if equipped, Fig. 9.
5. Install synchronizer ring, retaining ring, synchronizer rings, synchronizer assembly, retaining ring, synchronizer rings, retaining ring, bearing, second speed gear, retaining pin, thrust washer, retaining ring, spacer, bearing, clutch gear and synchronizer ring.
6. Install third speed gear and synchronizer assembly.
7. Install synchronizer ring and clutch gear.