Input Shaft

DISASSEMBLE
Identify blocker ring for third (14) and fourth gear (7). Do not intermix.

1. Remove snap ring (2).

2. Remove fifth gear (3) using press, gear remover tool No. J-36513 and adapter tool No. J-39473, or equivalents.

3. Remove fourth gear (4), bearing (5) and blocker ring (7).

4. Remove 34 synchronizer hub (8) using 3 bolt universal puller and three 5 x M8 x 1.25 inch bolts.

5. Remove needle race (6), thrust bearing race (15), thrust bearing (16) and thrust bearing race (17).

6. Remove third gear blocker ring (14), third gear (18), cage bearing (19), bronze thrust washer (20) and thrust washer (21).


ASSEMBLE
Lubricate all components as assembly progresses. Heat needle bearing race (6) and fifth gear (3) in an oven to 250°F for 7-10 minutes prior to installation.

1. Install standard and bronze thrust washers (20 and 21) with bronze side facing downward.

2. Install cage bearing (19) and third gear (18) with cone facing upward.

3. Install third gear blocker ring (14). Ensure correct blocker ring is being installed.

4. Install thrust bearing race (15), thrust bearing (16), and thrust bearing race (17), noting the following:

a. Ensure groove of thrust bearing race (15) faces downward.

b. Stop press operation before tangs engage.

c. Lift and rotate gear (18) into synchronizer tangs.

d. Continue to press until seated.

e. Ensure all shavings are removed.

5. Install 3-4 synchronizer (8) with flat side of inner hub toward third gear (18) using press tube tool No. J-36183, press tube adapter tool No. J-39371 and input shaft support tube tool No. J-39472, or equivalents, and a press.

6. Install needle bearing race (6), needle bearing (5) and fourth gear blocker ring (7).

7. Install fourth gear (4) with cone down, then the fifth gear (3) with grooved side down.

8. Select appropriate snap ring (2) as outlined under "Shim Selection." Refer to Shim Selection