Input Shaft & Mainshaft

DISASSEMBLY

1. Separate input shaft from mainshaft assembly.
2. Remove front bearing race, then the front bearing using tools BVI-FM-07 and BVI-FM-09 or equivalents and a suitable press.
3. Remove input shaft pilot bearing race using tool No. BVI-FM-10 or equivalent.
4. Mark 3rd-4th synchronizer and hub for assembly reference, then remove synchronizer from hub.
5. Remove mainshaft pilot bearing and preload shims using tool No. BVI-FM-21 or J-22912-01 or equivalent and a suitable press.
6. Remove snap ring, spring washer, 3rd gear and 3rd gear needle bearing from mainshaft.
7. Remove reverse gear nut and washer (if equipped), then the reverse gear, rear bearing retainer and rear bearing race from mainshaft.
8. Press rear bearing approximately 3/4 off mainshaft using tool No. BVI-FM-07 or equivalent and suitable press.
9. Mark 1st-2nd synchronizer and hub for assembly reference, then tap rear bearing off mainshaft using a soft faced mallet.
10. Remove shim, spacer, 1st gear, 1st gear needle bearing, bearing spacer, 1st-2nd synchronizer, synchronizer hub, 2nd gear and 2nd gear bearing from mainshaft.Note position of synchronizer lugs for assembly reference.

ASSEMBLY

1. Press pilot bearing race into input shaft using tool No. BVI-FM-12 or equivalent and a suitable press.
2. Install input shaft front bearing using tools BVI-FM-12 and BVI-FM-13 or equivalents and a suitable press.
3. Install 1st gear bearing, bearing spacer, 2nd gear bearing and 2nd gear on mainshaft.
4. Install hub assembly and 1st-2nd synchronizer on mainshaft. Ensure synchronizer lugs face rear of mainshaft.
5. Install rear bearing preload shim on mainshaft. The original shim should be installed if all original transmission components, except bearings and races, are being reused. If any other transmission components are being replaced, a 0.179 inch thick replacement shim should be installed.
6. Install mainshaft rear bearing using tool No. BVI-FM-13 or equivalent and a suitable press. Do not exceed 6600 lbs. pressure when installing bearing.
7. Position 3rd gear needle bearing and 3rd gear onto front of mainshaft.
8. Install 3rd-4th synchronizer hub on mainshaft.
9. Install a new spring washer and lock ring on mainshaft. Seat lock ring as follows:
a. Secure mainshaft assembly in a suitable press
b. Position tool No. BVI-FM-13 or equivalent over end of mainshaft and against lock ring.
c. Apply only enough pressure to align lock ring with groove in mainshaft.
d. Compress lock ring with pliers to secure it in groove in shaft.
e. Remove mainshaft and tools from press.
10. Install pilot bearing shims on mainshaft. The original shims should be installed if original 3rd gear, synchronizer hub, spring washer and lock ring are being reused. If any of these components are being replaced, shims having a total thickness of 0.110 should be installed.
11. Install mainshaft pilot bearing using tool No. BVI-FM-14 or equivalent and a suitable press.
12. Install 3rd-4th synchronizer on hub, ensuring reference marks made during disassembly are properly aligned.