Operation CHARM: Car repair manuals for everyone.

Output Shaft Geartrain Disassembly

Disassembly - Output Shaft Geartrain

Remove the thrust bearing washer from the front end of the output shaft.





Scribe alignment marks (A) on the third-fourth gear synchronizer hub and sleeve for assembly reference.





Position the jaws of a split-type puller (e.g., Tool J-22912-O1) between the third and second gears on the output shaft. Ensure that the puller jaws exert force firmly against the back of the third gear.

Position the output shaft (37) geartrain assembly in an arbor press and remove the third-fourth gear synchronizer hub and sleeve (38) and third gear (36) as an assembly.









Remove the snap ring (39) retaining the second gear on the shaft and remove the tabbed second gear thrust washer (40) and second gear (41).





Remove the output shaft rear bearing with Puller Set J-29721 and Adapter J-29721-9.





Remove the first gear thrust washer (42), first gear and blocking ring. Use diagonal (side) cutters to remove the roll pin.

NOTE: Some first gear journals have an hour glass shape.

Scribe alignment marks on the first-second gear synchronizer sleeve and output shaft hub for assembly reference.

Remove the insert spring and inserts from the first-reverse sliding gear and remove the gear from the output shaft hub.

CAUTION: Do not attempt to remove the first-second-reverse gear hub from the output shaft. The hub and shaft are machined and assembled as a matched set during manufacture to ensure concentricity.