Output Shaft

Main Drive Gear Bearings:

Mainshaft And Components:

Synchronizer And Components:

DISASSEMBLE
1. Remove thrust bearing washer from front end of output shaft.
2. Mark 3rd-4th synchronizer hub and sleeve for assembly reference, then remove blocking ring, sleeve and hub as assembly.
3. Remove 3rd-4th synchronizer insert springs and remove inserts, then remove sleeves from hubs.
4. Remove 3rd gear from shaft, then remove snap ring retaining 2nd gear on shaft and remove tabbed 2nd gear thrust washer and 2nd gear.
5. Using bearing remover tool No. J-22912-01 or equivalent, remove output shaft rear bearing.
6. Remove 1st gear thrust washer, 1st gear roll pin, 1st gear and blocking ring.
7. Mark alignment of 1st-2nd gear synchronizer sleeve and output shaft hub for assembly reference, then remove insert spring and inserts from 1st-reverse sliding gear and remove gear from output shaft hub. Do not try to remove 1st-2nd-reverse hub from output shaft as hub and shaft are assembled and machined as a matched set during manufacture to insure concentricity.

ASSEMBLE

Fig. 4 Synchronizer Spring Location:

1. Lubricate output shaft and gear bores, then install and align 1st-2nd synchronizer sleeve on output shaft hub using assembly reference marks. If any output shaft gear is replaced, countershaft gear must also be replaced to maintain proper gear mesh and avoid noisy operation.
2. Install 3 1st-2nd synchronizer inserts and 2 insert springs in 1st-reverse synchronizer sleeve. Engage tang end of each spring in same synchronizer insert, but position open ends of insert springs to face 180° from each other Fig. 4. Check alignment of sleeve and hub using assembly reference marks.
3. Install blocking ring and 2nd gear on mainshaft, then install tabbed thrust washer and 2nd gear retaining snap ring on mainshaft, ensuring washer tab is properly seated in mainshaft notch.
4. Install blocking ring and 1st gear on output shaft and install 1st gear roll pin in output shaft.
5. Using bearing installer tool No. J-2995 or equivalent and suitable press, install rear bearing on output shaft and install 1st gear thrust washer.
6. Install 3rd gear, 3rd-4th gear synchronizer hub inserts and sleeve on shaft with hub offset facing forward, then install thrust bearing washer on forward end of shaft.