Mainshaft Assemble (Four Wheel Drive)

MAINSHAFT ASSEMBLY

- Tools Required
- Hydraulic Press
- J 36183 Input Shaft Press Tube with Cap
- J 36184 Adapter Press Tube Reducer
- J 39924-1 Reverse Drag Seal Installer
- J 39924-2 5th Speed Gear Drag Seal Installer

IMPORTANT: Some components require an assembly lubricant. Use TRANSJEL(R) or equivalent.





1. Install the 5th speed gear drag seal. Use J 39924-2 and J 36183.





2. Install the reverse speed gear drag seal. Use J 39924-1.





3. Install the following components:
3.1. The reverse speed gear needle bearing assembly.
3.2. The reverse speed gear.





4. Install the 5th/Reverse speed gear synchronizer.
4.1. Check the scribe marks for the correct positions.
4.2. Position the spiral lock ring towards the reverse speed gear.
4.3. Manually align and engage the splines.
4.4. Use J 36183 and J 36184.
4.5. Press the synchronizer until seated.
4.6. Remove all the metal shavings.





5. Install a new mainshaft snap ring.





6. Install the following components:
6.1. The 5th speed gear needle bearing assembly
6.2. The synchronizer ring
6.3. The 5th speed gear





7. Install the 1st speed gear needle bearing assembly

IMPORTANT: The groove on the outside of the synchronizer sleeve must go towards the 2nd speed gear. This prevents gear clash during 1st and 2nd speed gear shifts. The teeth of the sleeve have different angles.





8. Install the following components:
8.1. The 1st speed gear
8.2. The synchronizer interim ring
8.3. The reaction cone
8.4. The blocker ring
8.5. The synchronizer cone





9. Check the 1st/2nd speed gear synchronizer assembly scribe marks for correct positions.





10. Install the 1st/2nd speed gear synchronizer assembly with both synchronizer rings:
10.1. Manually align and engage the splines.
10.2. Use J 36183 and J 36184 and a hydraulic press.
10.3. Start the press operation.
^ Stop pressing before the tangs engage.
^ Lift and rotate the gear.
^ Engage the synchronizer ring.

10.4. Press the synchronizer until seated.
10.5. Remove all the metal shavings.





11. Install a new mainshaft snap ring.





12. Install the following components:
12.1. The synchronizer cone
12.2. The blocker ring
12.3. The reaction cone
12.4. The interim ring





13. Install the following components:
13.1. The 2nd speed gear needle bearing assembly
13.2. The 2nd speed gear Make sure the bearing cage is together.





14. Install the following components:
14.1. The 2nd speed gear 2-piece thrust washer (Install the 2-piece thrust washers with the locating dots facing up.)
14.2. The retainer ring





15. Install the following components:
15.1. The 3rd speed gear needle bearing assembly
15.2. The 3rd speed gear
15.3. The synchronizer ring





16. Check the 3rd/4th speed gear synchronizer assembly scribe marks for correct positions.





17. Install the 3rd/4th speed gear synchronizer assembly with both synchronizer rings.
17.1. Manually align and engage the splines.
17.2. Use tools J 36183 and J 36184, and a hydraulic press.
17.3. Start the press operation.
17.3.1. Stop pressing before the tangs engage.
17.3.2. Lift and rotate the gear.
17.3.3. Engage the synchronizer ring.
17.4. Press the synchronizer until seated.
17.5. Remove all the metal shavings.





18. Install a new mainshaft snap ring.