Output Shaft

Fig. 31 Output shaft gear thrust clearance measurement:

DISASSEMBLY

1. Measure thrust clearance of the output shaft first, second and third gears with a feeler gauge as shown. Clearance should be as follows:
a. First gear, 0.003-0.0197 inch.
b. Second and third gears, 0.003-0.0118 inch.
c. If first gear clearance is not as specified, replace gear and thrust washer.
d. If second and third gear is not as specified, either gear and bearing are worn or output shaft flange is worn. Refer to "INSPECTION" before replacing gears or thrust washers.
2. Press fifth gear and rear bearing off rear of output shaft.
3. Remove thrust washer, pin, first gear and bearing.

Fig. 32 Output shaft & components:

4. Remove first/reverse hub snap ring.
5. Remove synchro ring, then press reverse gear and first/reverse hub off shaft as an assembly.
6. Remove remaining synchro ring, second gear and bearing.
7. Remove snap ring front of output shaft.
8. Press hub 3-4 sleeve from output shaft as an assembly, then remove synchro ring.
9. Remove third gear and needle bearing.

INSPECTION

1. Inspect components for excessive wear and/or damage. Replace worn or damaged components as necessary.

Fig. 33 Output shaft tolerance measurement:

2. Measure thickness of output shaft flange with a micrometer as shown. Minimum allowable flange thickness is 0.185 inch. If thickness is less than specified, replace gear and needle bearing as an assembly.
3. Measure diameter of first, second and third gear bearing surfaces of output shaft. Minimum allowable diameters are as follows:
a. First gear, 1.529 inch.
b. Second gear, 1.844 inch.
c. Third gear, 1.490 inch.
4. Measure output shaft runout using V-blocks and dial indicator. Maximum allowable run is 0.0024 inch. If runout is not as specified, replace output shaft.

Fig. 34 Cluster gear journal diameter measurement:

5. Measure diameter of cluster gear journal with a micrometer as shown. Clearance should be 1.096 inches.

Fig. 35 Synchro ring end clearance measurement:

6. Measure end clearance between synchro ring and gear with feeler gauge as shown. Clearance should be 0.024-0.063 inch.

Fig. 36 Gear to shaft clearance measurement:

7. Measure shaft to gear clearance with a dial indicator as shown. Clearance should be 0.0063 inch. If any gear exhibits excessive clearance, replace gear and needle bearing.

Fig. 37 Shift fork to sleeve clearance measurement:

8. Measure clearance between shift forks and synchro sleeves using a feeler gauge as shown. Clearance should be 0.039 inch. If clearance is not as specified, replace synchro sleeve and matching hub.

Fig. 38 Reverse idler gear bushing:

9. Check condition of reverse idler gear bushing. Replace gear if bushing is damaged or worn.
10. Inspect reverse pin in extension housing, replace as necessary.

ASSEMBLY

1. Apply gear lubricant to output shaft journals, gears and needle bearing.
2. Install third gear, needle bearing and synchro ring on shaft.

Fig. 39 Synchro & hub identification:

3. Assemble 1st-2nd and 3rd-4th synchro hubs and sleeves.

Fig. 40 Insert spring position:

4. Install inserts and springs in synchro sleeves. Position open ends of springs 180° apart as shown.
5. Install 3rd-4th synchro hub and sleeve on output shaft. Press hub onto shaft if necessary.

Fig. 41 3-4 synchro installation & select snap ring chart:

6. Install 3rd-4th synchro hub snap ring. Use thickest snap that can be installed.
7. Check third gear thrust clearance using a feeler gauge. Clearance should be 0.004-0.010 inch.
8. Apply gear lubricant to output shaft gear and bearings.

Fig. 42 Second gear, synchro assembly & select snap ring chart:

9. Install second gear and needle bearing on shaft.
10. Assemble first/reverse hub, then insert springs, reverse gear and 1st-2nd sleeve. Ensure springs ends are 180° apart and splines in hub bore are chamfered on one side. Install hub so chamfered side faces front of output shaft.
11. Press assembled hub and sleeve on output shaft, then install selective snap ring. Use thickest snap ring that can be installed.
12. Install synchro ring on first gear and spacer on shaft against selective snap ring.
13. Install first gear, needle bearing, locating pin and thrust washer on output shaft.
14. Press rear bearing on shaft, then position bearing snap ring groove to end of output shaft.
15. Measure first and second gear thrust clearance using a feeler gauge. First gear clearance should be 0.003-0.0197 inch. Second gear clearance should be 0.003-0.0118 inch.

Fig. 43 Fifth gear & select snap ring chart:

16. Press fifth gear onto output shaft, then install select fit snap ring. Use thickest snap ring that can be installed.
17. Lubricate input shaft pilot bearing with petroleum jelly, then install bearing in shaft.
18. Install input shaft on output shaft. Ensure output shaft hub is fully seated in pilot bearing.