Disassembly

DISASSEMBLY

NOTE: When servicing the input shaft assembly, all snap rings, which are removed MUST be replaced with new snap rings upon reassembly. The 5th gear nut must be replaced also.

1. Invert input shaft assembly and place in fixture 8487.





2. Remove input bearing snap ring (Fig. 206).





3. Remove input bearing. Place input shaft assembly onto arbor press table, with the input bearing supported by bearing splitter (Fig. 207). Using adapter 8486-4, press bearing off of shaft, while helper supports shaft to prevent dropping.
4. Place input shaft assembly back into fixture 8487. Secure fixture to bench with fasteners, or secure to bench vise.

NOTE: 5th gear nut is staked to the shaft. If necessary, grind stake area to ease removal, but use care not to contact gear.





5. Remove 5th gear nut with wrench 8478 (Fig. 208). Discard nut and use a new one upon assembly.
6. Remove 5th gear with arbor press and bearing splitter.





7. Remove 4th gear (Fig. 209).





8. Remove 4th gear blocker ring (Fig. 210).





9. Remove 3/4 synchronizer snap ring (Fig. 211). Discard and replace with new snap ring upon assembly.





10. Remove 3/4 synchronizer (Fig. 212).





11. Remove 3rd gear blocker ring (Fig. 213).





12. Remove 3rd gear (Fig. 214).
13. Inspect third gear thrust washer for signs of excessive wear. To replace, drive off of input shaft with suitable drift and hammer.