Output Shaft and Cluster Gear

DISASSEMBLY
1. Remove output shaft rear bearing snap ring.
2. Remove cluster gear rear bearing snap ring.





3. Tap end of output shaft with mallet to unseat and start rear bearing out of intermediate plate.





4. Remove output shaft by rocking it lightly until rear bearing comes out of intermediate plate.





5. Remove cluster gear by pulling it straight out of rear bearing.





6. Remove cluster gear rear bearing from intermediate plate.





7. Remove input shaft from output shaft.





8. Remove output shaft pilot bearing from input shaft.





9. Remove synchro ring from input shaft.
10. Remove bearing snap ring and press bearing off input shaft.






ASSEMBLY
1. Mount intermediate plate in vise.
2. Lubricate cluster gear journal and rear bearing with petroleum jelly or gear lubricant.





3. Install cluster gear rear bearing in intermediate plate. Be sure snap ring groove in bearing is rearward as shown.
4. Start cluster gear into bearing. Then hold bearing and push gear into place. Use plastic or rawhide mallet to seat bearing if necessary.
5. Start output shaft rear bearing in intermediate plate. Push shaft rearward and tap intermediate plate with mallet to seat bearing.





6. Install snap rings on cluster and output shaft rear bearings only. Do not install front bearing snap rings at this time.





7. Install reverse idler gear and shaft.





8. Position rear bearing retainer over output shaft and rear bearing. Be sure bearing retainer tab is engaged in reverse idler shaft notch.
9. Install and tighten rear bearing retainer bolts to 18 Nm (13 ft. lbs.).