Assembly

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

1. Install anti-rattle spring and ball in hub.

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

3. Install three first-second synchronizer inserts and two 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° apart. Check alignment of sleeve and hub using assembly reference marks.

4. Install the three-piece first gear blocking ring assembly, then place locating pin in the mainshaft.

5. Install sleeve and bearing onto mainshaft, aligning notch in sleeve with locating pin.

6. Install first gear, aligning slots in first gear with tabs on blocker ring assembly.

7. Install rear mainshaft bearing with taper facing rear of shaft.

8. Lubricate fifth gear splines with petroleum jelly and position on output shaft Using a press and a capped of pipe (1 1/4 X 14 inches) press fifth gear onto output shaft.

Caution: Ensure output shaft and gear splines are carefully aligned. Damage can occur if not aligned properly before pressing gear onto output shaft.

9. Install fifth ears nap ring, then second gear blocker ring assembly and thrust washer.

10. Install spiral snap ring, using installer tool No. J37360 or equivalent.

11. Install second gear spacer, needle bearing and gear, aligning slots in second ear with tabs on blocker ring assembly.

12. Install second gear thrust washer and snap ring.

13. Install third gear, spacer and needle bearing assembly. Ensure bearing spacer is not trapped between the gear face and snap ring. The spacer runs inside the gear bore.

14. Install third-fourth synchronizer, third blocker ring and third gear as an assembly, using installation tool No. J-37372 and a suitable press.