Assembly

Fig. 15, Output shaft components, installation:

Refer to Fig. 15, and proceed as follows:
An oven, hydraulic press, tools J-36183 and J-36184 are required to conduct the following procedure. Also, bearing race (40) requires heating to approximately 250°F, in an oven for 7-10 minutes. 3rd-4th gear cluster (37) requires heating to approximately 250°F, in an oven for 20 minutes MINIMUM. Lubricate all components as assembly progresses with lubricant No. 12345349 or equivalent.

1. Install thrust washer (52) with chamfer facing downward.
2. Install caged thrust bearing (51) with needles facing downward.
3. Install 1st gear bearing (50) and 1st gear (49) with cone facing upward.
4. Install blocker ring (48).
5. When pressing the 1st-2nd synchronizer assembly (42), note the following:
a. Start the press operation, then STOP, before tangs engage.
b. Lift and rotate gears (49) and (48), to engage blocker ring tangs.
c. Continue to press until seated. Ensure all shavings are removed.
6. Install 1st-2nd synchronizer (42), using tools described previously. The side marked 1ST and small outside diameter groove on the sleeve must face toward the first gear (49).
7. Install 2nd gear bearing race (40), bearing (39) and 2nd gear (38) with cone facing downward.
8. Install 3rd-4th gear cluster (37), using tools described previously. Install with large outside diameter gear facing downward.
9. Install snap ring (36), thrust washer ball (34, retain ball using petroleum jelly) and slotted thrust washer (35). Align inside diameter slot with ball (34).
10. Install 5th gear bearing (33) and 5th gear (32).
11. Install blocker ring (31).
12. When installing reverse gear and 5th synchronizer (25), note the following:
a. Start the press operation, then STOP, before tangs engage.
b. Lift and rotate 5th gear (32) and blocker ring (31). Thrust washer (35) must stay down. engaging tangs.
c. Continue to press until seated. Ensure all shavings are removed.
13. Install reverse gear and 5th gear synchronizer assembly (25), using tools described previously.