Output Shaft

OUTPUT SHAFT

DISASSEMBLY





1. Install output shaft to fixture 8925-3.(5) Use split plate 8925-2 on diesel models, and 8925-4 (4) on turbo models.
2. Remove 4th (3) and 5th gears (2) simultaneously. Install protective sleeve 8918 (1) to output shaft and press 4th and 5th gears off of shaft.





3. Install output shaft to fixture 8925-3 (2) using split plate 8925-1 (3).
4. Remove 3rd gear (1). Install protective sleeve 8918 (1) to output shaft and press 3rd gear (2)off of shaft.
5. Remove second gear from output shaft.
6. Remove second gear needle bearing.





7. Install output shaft to fixture 8925-3 using split plate 8925-2 (5)(inverted).
8. Install protective sleeve 8918 (1) to output shaft and simultaneously press off 2nd gear bushing, 1-2 synchronizer (3), and 1st gear (4).





9. Remove 1st gear needle bearings (12) from shaft. Inspect thrust washer (fixed to shaft).

ASSEMBLY









1. Install first gear roller bearing (1) to shaft with smaller diameter cage ring (2) facing outward.





2. Install first gear (1).





3. Install other first gear roller bearing (2) with larger diameter cage ring (1) facing outward.





4. Install first gear friction cone (1).





5. Install first gear friction ring (1). Align teeth of friction ring with notches in gear.





6. Install first gear blocker ring (1).





7. Install 1/2 synchronizer hub with Installer 6448A (3).





Line up blocker ring (2) with the synchronizer hub (1).





8. Install 1/2 synchronizer sleeve (1) with groove towards first gear (2).





9. Install three synchronizer strut (1) assemblies.





10. Using Installer 6448A (1), install second gear bearing bushing (2) until it bottoms on synchronizer hub.





11. Install second gear needle bearing (1).





12. Install second gear blocker ring (1).





13. Install second gear friction ring (1).





14. Install second gear friction cone (1). All parts should be flush.





15. Install second gear (3). Engage friction ring teeth with notches in gear. Components are properly installed when flush.





16. Using Installer 6448A (1), press third gear (2) until it bottoms.





17. Using Installer 6448A (1), press fourth gear (collar down) (2) until it bottoms.





18. Using Installer 6448A (1), press fifth gear (collar up) (2) until it bottoms.