Output Shaft

DISASSEMBLE
Identify blocker ring for fifth, second and first gears. Do not intermix.

1. Remove fifth gear (38) and bearing (39) using press, split plate tool No. J-39428 and press adapter tool No. J-22919, or equivalents.

2. Remove thrust washer (41) and positioning ball (40).

3. Remove and discard third gear snap ring (42).

4. Remove 3-4 gear cluster (43) using hydraulic press, split plate tool No. J-39428 and press adapter tool No. J-22919, or equivalents.

5. Remove second gear (44), bearing (45) and blocker ring (47).

6. Remove first gear using split plate tool No. J-36513 and press adapter tool No. J-22919, or equivalents, and V-blocks and hydraulic press.

7. Remove first gear bearing (56).

8. Remove and discard output shaft support bearing (58) using split plate tool No. J-39372 and press adapter tool No. J-39423, or equivalents, and a press.

ASSEMBLE
Lubricate all components as assembly progresses. Heat second gear output bearing race (46) in an oven to 250°F for 7-10 minutes prior to installation. The 3-4 gear cluster (43) requires heating to 250°F for a minimum of 20 minutes.

1. Install output shaft support bearing (58) using press adapter tool No. J-39373, or equivalent.

2. Install first gear bearing (56) with smaller outside diameter side of plastic bearing cage toward center of first gear (55).

3. Install first gear and bearing, cone up, with smaller outer diameter side of plastic bearing cage toward center of first gear.

4. Install first gear blocker ring (54).

5. Install 1-2 synchronizer (48) using press tube tool No. J-36183, press tube adapter tool No. J-39371 and press adapter tool No. J-39373, or equivalents, and a press, noting the following:

a. Sleeve extension should face toward first gear.

b. Stop press operation before tangs engage.

c. Lift and rotate gear (55) to engage blocker ring tangs.

d. Continue to press until seated.

e. Ensure all shavings are removed.

6. Install second gear bearing race (46), bearing (45) and second gear (44).

7. Install 3rd gear cluster (43) with the large outside diameter gear down using press tube tool No. J-36183, press tube adapter tool No. J-39371 and press adapter tool No. J-39373, or equivalents, and a press.

8. Select new snap ring (42) as outlined under "Shim Selection". ,Refer to Shim Selection.

9. Install new snap ring (42), thrust washer positioning ball (40) (retained with petroleum jelly) and slotted thrust washer (41), aligning ID slot with ball.

10. Install fifth gear bearing (39) and gear (38) with cone facing upward, then the blocker ring (37).

11. Install fifth gear synchronizer (32) using hydraulic press and fifth gear synchronizer installer tool No. J-39471, or equivalent, noting the following:

a. Ensure snap ring on synchronizer hub faces away from fifth gear.

b. Stop press operation before tangs engage.

c. Lift and rotate fifth gear (32) and blocker ring (37) (thrust washer must stay down), engaging tangs.

d. Continue to press until seated.

e. Ensure all shavings are removed.

12. Install output shaft bearing (30) using press adapter tool No. J-39373 and output shaft bearing installer tool No. J-5590, or equivalents, and hydraulic press.