Output Shaft Service

DISASSEMBLY
1. Remove thrust bearing washer from front end of output shaft.

2. Mark third-fourth synchronizer hub and sleeve for assembly reference, then remove blocking ring, sleeve, and hub as assembly.

3. Remove third-fourth synchronizer insert springs and remove inserts, then remove sleeves from hubs.

4. Remove third gear from shaft, then rem6ve snap ring retaining second gear on shaft and remove tabbed second gear thrust washer and second gear.

5. Using tool J-29721 and adapters 293-39 or equivalent, remove output shaft rear bearing.

6. Remove first gear thrust washer, first gear roll pin, first gear, and blocking ring.

7. Mark alignment of first-second gear synchronizer sleeve and output shaft hub for assembly reference, then remove insert spring and inserts from first-reverse sliding gear and remove gear from output shaft hub.

CAUTION: Do not try to remove the first- second-reverse hub from the output shaft as the hub and shaft are assembled and machined as a matched set during manufacture to insure concentricity.


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

2. Install 3 first-second synchronizer inserts and 2 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 degrees from each other. Check alignment of sleeve and hub using assembly reference marks.

3. Install blocking ring and second gear on mainshaft, then install tabbed thrust washer and second gear retaining snap ring on mainshaft, making sure washer tab is properly seated in mainshaft notch.

4. Install blocking ring and first gear on output shaft and install first gear roll pin in output shaft.

5. Using tool J-2995 or equivalent, and suitable press, install rear bearing on output shaft and install first gear thrust washer.

6. Install third gear, third and fourth gear synchronizer hub inserts, and sleeve on shaft with hub offset facing forward, then install thrust bearing washer on forward end of shaft.