Mainshaft

DISASSEMBLY

1. Remove clutch gear snap ring, then remove clutch gear, synchronizer outer stop ring to third speed gear shim(s) and third gear.
2. Using two screwdrivers, remove split lock ring, then remove second speed gear and synchronizer.
3. Remove first and reverse sliding gear.

ASSEMBLY

When assembling subassemblies, use new expansion plugs, gaskets and seals. Lubricate all parts with clean transmission lubricant. Where grease is recommended, use oil soluble grease. Ensure oil return passages are not obstructed with grease.

1. Place mainshaft in soft jawed vise with rear end up and install first and reverse gear, ensuring two spline springs (if used) are inside of gear.
2. Reverse mainshaft in vise with forward end up.
3. Assemble second speed synchronizer spring and synchronizer brake to second speed gear, then install snap ring, ensuring snap ring tangs are facing away from gear.
4. Slide second speed gear onto front of output shaft. Ensure synchronizer brake is toward rear, then install the two piece lock ring and install third speed gear.
5. Install shim(s) between third speed gear and third and fourth speed synchronizer stop ring. Check endplay. If endplay is not within 0.050-0.070 inch, add or remove shims as necessary to bring endplay to specifications.