Mainshaft Assemble

Mainshaft Assemble

^ Tools Required
- J 22828 Input and Countershaft Race Installer
- J 22834-A Extension Housing Seal Installer





1. Position the mainshaft in a soft jaw vice, with the output end up.
2. Lubricate the 1st speed gear bearing with transmission fluid.
3. Install the 1st speed gear bearing.
4. Install the 1st speed gear, with the sector teeth facing down.





5. Install the reverse gear clutch gear and the synchronizer ring. Ensure that the side of the synchronizer with ring teeth are toward the mainshaft shoulder.
6. Install the reverse gear clutch gear retainer ring.





7. Install the mainshaft bearing spacer on top of the retaining ring.
8. Lubricate the reverse speed gear bearing with transmission fluid.
9. Install the reverse speed gear bearing.





10. Install the reverse gear assembly. Rotate the assembly until the gear drops into the fully seated position. If the synchronizer assembly was disassembled, the synchronizer sleeve must be reinstalled with the taper of the sleeve toward the reverse gear.
11. Install the reverse gear thrust washer.
12. Position the rear mainshaft bearing on the mainshaft.





13. Using a hydraulic press and the J 22828, install the rear mainshaft bearing.
14. Turn the mainshaft over and install it into a soft jaw vice, with the front facing up.





15. Install the following 1st/2nd gear synchronizer components:
^ The 1st speed gear synchronizer outer ring retaining ring (11) in the lower groove
^ The 1st speed gear synchronizer inner ring (10) The 1st speed gear outer ring retainer ring (9) in the second groove
^ The 1st speed gear synchronizer center ring (8) Turn, to align in first gear.
^ The 1st speed gear synchronizer outer ring (7)
^ The 1st/2nd speed synchronizer assembly (6)
^ The tapered side of the sleeve faces up. Turn the 1st speed gear synchronizer rings to align in the synchronizer assembly.
^ The 2nd speed gear synchronizer outer ring (5) Turn the ring, to align the tabs in the synchronizer assembly.
^ The 2nd speed gear synchronizer center ring (4)
^ The 2nd speed gear synchronizer outer ring retaining ring (3) in the third groove
^ The 2nd speed gear synchronizer inner ring (2)
^ The 2nd speed gear synchronizer outer ring retaining ring (1) in the top groove





16. Lubricate the 2nd speed bearing with transmission fluid.
17. Install the 2nd speed gear bearing.





18. Install the 2nd speed gear. Turn the gear, to align the inner synchronizer ring tabs in the gear.





19. Install the following parts:
19.1. The 2nd speed gear thrust washer retaining pin
19.2. The 2nd speed gear thrust washer. Be sure the thrust washer is seated on the gear and the retaining pin.
19.3. The 2nd speed gear thrust washer retainer ring





20. Install the mainshaft bearing spacer.
21. Lubricate the 3rd speed gear bearing with transmission fluid.
22. Install the 3rd speed gear bearing.





23. Using the J 22834-2A of J 22834-A, install the 3rd /4th synchronizer in the mainshaft. Align the synchronizer rings to the synchronizer while installing.





24. Install the main drive gear thrust bearing.
25. Install the 4th speed gear synchronizer ring.
26. Install the 4th speed gear clutch gear.