Output Shaft Disassembly

OUTPUT SHAFT DISASSEMBLY

NOTE: The synchronizer hubs and sleeves are different and must not be intermixed. It is recommended that each synchronizer unit be removed as an assembly to avoid intermixing parts. It is also recommended that each synchro hub and sleeve be marked with a scriber or paint for correct assembly reference.

1. Remove snap ring that secures 3-4 synchro hub on output shaft.
2. Remove 3-4 synchro assembly, third gear synchro ring, and third gear with shop press and Remover Tool 1130. Position Tool 1130 between second and third gears.

Third Gear Needle Bearing Removal:

3. Remove third gear needle bearing.

Thrust Washer Retaining Ring Removal:

4. Remove retaining ring that secures two-piece thrust washer on shaft. Use small pry tool to remove retaining ring.

Two-Piece Thrust Washer Removal:

5. Remove two-piece thrust washer. Note position of washer locating lugs in shaft notches for installation reference.

Second Gear And Needle Bearing Removal:

6. Remove second gear and needle bearing.

Second Gear Synchro Ring And Cones Removal:

7. Remove second gear synchro ring, synchro friction cone, and synchro cone.
8. Remove interim ring.
9. Remove 1-2 synchro hub snap ring.

Hub And Sleeve Removal-1-2 Synchro:

10. Remove 1-2 synchro hub and sleeve and first gear from output shaft with shop press and Remover Tool 1130. Position Tool 1130 between first and reverse gears.