Assembly

CAUTION: If any output shaft gear is replaced, the countershaft gear must also be replaced to maintain proper gear mesh and avoid noisy operation.

1. Lubricate output shaft and gear bores, then install and align first-second synchronizer sleeve on output shaft hub using assembly reference marks.

2. Install 3 first-second synchronizer inserts and 2 insert springs in first-reverse synchronizer sleeve. Engage tang end of each spring in same synchronizer insert but position open ends of insert springs to face 180 degrees from each other. Check alignment of sleeve and hub using assembly reference marks.

3. Install blocking ring and second gear on mainshaft, then install tabbed thrust washer and second gear retaining snap ring on mainshaft, making sure washer tab is properly seated in mainshaft notch.

4. Install blocking ring and first gear on output shaft and install first gear roll pin in output shaft.

5. Usin tool J-2995 or equivalent, and suitable press, install rear bearing on output shaft and install first gear thrust washer.

6. Install third gear, third and fourth gear synchronizer hub inserts, and sleeve on shaft with hub offset facing forward, then install thrust bearing washer on forward end of shaft.