2. Mainshaft and Input Shaft Disassemble
^ Tools Required^ J 36513 Split Plate
^ J 39442 Press Adapter
^ J 39443 Split Plate
^ J 39473 Bearing Installer/Press Adapter
Important: Measure the 4th speed gear synchronizer wear gap before disassembling the mainshaft.
1. Install the input shaft in the adapter plate.
2. Install the mainshaft on the input shaft.
3. Using a feeler gauge measure the gap between the 4th speed gear blocking ring and the 4th speed gear.
4. Replace the 4th speed gear blocking ring when the gap is less than 0.65 mm (0.025 inch).
5. Remove the following parts in order:
5.1. The mainshaft large tapered bearing
5.2. The 1st speed gear
5.3. The 1st speed gear caged needle bearing
5.4. The 1st speed bearing spacer
6. Remove the following parts in order:
6.1. The retainer ring
6.2. The 1st speed gear inner cone
6.3. The 1st speed gear friction cone
6.4. The 1st speed gear blocking ring
Important: The synchronizer hubs and sliding sleeves are a selected assembly. Keep these parts together as originally assembled.
7. Scribe a mark on the synchronizer hub and on the sleeve. This will help you to reinstall the parts in the same position.
8. Remove the 2nd speed gear, using the J 36513 and a hydraulic press. The 1st/2nd speed synchronizer assembly, the 2nd speed gear blocking ring, the 2nd speed gear friction cone, and the 2nd speed gear inner cone will press off with the 2nd speed gear.
9. Remove the 2nd speed gear spacer and caged needle bearing.
10. Remove the mainshaft small tapered bearing, using the J 39442, the J 39443, and a hydraulic press.
11. Discard the small tapered bearing.
12. Remove the 3rd/4th speed synchronizer retainer ring.
Important: The synchronizer hubs and sliding sleeves are a selected assembly. Keep these parts together as originally assembled.
13. Scribe a mark on the synchronizer hub and on the sleeve. This will help you to reinstall the parts in the same position.
14. Remove the 3rd speed gear, using the J 39473, V-blocks, and a hydraulic press. The 3rd/4th speed synchronizer assembly, and the 3rd speed gear blocking ring will press off with the 3rd speed gear.
15. Remove the 3rd speed gear caged needle bearing.
Input Shaft
^ Tools Required
^ J 22912-01 Split Plate
^ J 23907 Slide Hammer
^ J 39594 Bearing Race Remover
Important: Do not replace the tapered bearing or the bearing race unless inspection shows that the bearing or the race are damaged.
1. Remove the tapered bearing from the input shaft, using the J22912-01 and a hydraulic press.
2. Remove the bearing race from the input shaft, using the J 23907 and the J 39594.