m. Mainshaft Assemble 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 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 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 with the teeth up.
8.3. The reactor cone with the flat side towards 1st gear.
8.4. The blocker ring with the teeth down.
8.5. The synchronizer cone with the flat side down.





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, J 36184 and a hydraulic press,
10.3. Start the press operation.
10.3.1. Stop pressing before the tangs engage.
10.3.2. Lift and rotate the gear.
10.3.3. Engage the synchronizer ring.
10.4. Press the synchronizer until seated.
10.5. Remove all the metal shavings.





11. Install the following components:
11.1. The synchronizer cone with the flat up.
11.2. The blocker ring with the tangs up.
11.3. The reaction cone with the wide flat portion up.
11.4. The interim ring.





12. Install a new mainshaft snap ring.





13. Install the following components:
13.1. The 2nd speed gear needle bearing assembly.
13.2. The 2nd speed gear Ensure that the bearing cage is together. Ensure that the synchronizer ring gear teeth are toward 1st gear.





14. Install the following components:
14.1. The 2nd speed gear 2-piece thrust washer Ensure that the dots are facing up.
14.2. The retainer ring Ensure that the retainer ring is installed around the washer.





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. Ensure that the groove in the synchronizer ring faces upward.
17.1. Manually align and engage the splines.
17.2. Use J 36183, 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.