Output Shaft

Fig. 14 Disassembled view of output shaft:

DISASSEMBLY

1. Remove snap ring.
2. Press fifth gear, rear bearing, first gear and inner race from shaft, then remove needle bearing, synchronizer ring and locking ball.
3. Press No. 1 hub sleeve, synchronizer ring and second gear from shaft. Remove needle bearing.
4. Remove snap ring from opposite side of shaft, the press No. 2 hub sleeve, synchronizer ring and third gear from shaft. Remove needle bearing.

Fig. 15 Output shaft & inner race flange thickness measurement:

INSPECTION

1. Measure output shaft and inner race flange thickness. For the output shaft flange should be no less than 0.189 inch, while the race flange thickness should be no less than 0.157 inch. If thickness is less than specified, replace effected parts.
2. Measure output shaft journal diameter at second and third gear locations. Second gear journal surface diameter should be at least 1.495 inches, while third gear journal diameter should be 1.377 inches. If measurements are not specified, replace output shaft.
3. Measure outer diameter of inner race. Minimum diameter should be 1.535 inches. If diameter is not as specified, replace inner race.
4. Mount output shaft in V-blocks, then measure shaft runout with a dial indicator. maximum allowable runout is 0.002 inch. If runout exceeds specification, replace output shaft.

Fig. 16 Snap ring identification chart (input shaft side):

Fig. 17 Snap ring identification chart (rear bearing side):

ASSEMBLY

1. Apply gear lubricant to output shaft and third gear needle bearing, then position third gear synchronizer ring onto gear, ensuring ring slots align with shifting keys.
2. Install needle bearing between third gear and No. 2 hub sleeve, then press gear and hub sleeve onto output shaft.
3. Select a new snap ring from chart that will allow minimum axial play, then install snap ring onto output shaft.
4. Measure third gear thrust clearance should be 0.004-0.010 inch.
5. Apply gear lubricant to output shaft and second gear needle bearing, then position second gear synchronizer ring onto gear, ensuring ring slots align with shifting keys.
6. Install needle bearing into second gear, then press gear and No. 1 hub sleeve onto output shaft.
7. Insert first gear locking ball into output shaft, then apply gear lubricate to needle bearing.
8. Assemble first gear, synchronizer ring needle bearing and inner race.
9. Install assembly onto output shaft, ensuring synchronizer ring slots align with shifting keys.
10. Turn inner race until it aligns with locking ball, then press rear bearing onto shaft so outer race snap ring groove faces rearward. When pressing rear bearing onto shaft, hold first gear in place with a screwdriver.
11. Measure first and second gear thrust clearance with a feeler gauge, clearance should be 0.004-0.010 inch.
12. Press fifth gear onto shaft, then select a snap ring from chart that will allow minimum axial play. Install snap ring.