Output Shaft

Output Shaft

Special Tool(s):

Disassembly and Assembly
1. Remove the input shaft needle bearing.
^ Place the output shaft in the holder with the input end facing upward.





2. Remove the snap ring and the 4th gear synchronizer blocking ring. Discard the snap ring.
^ Inspect the blocking ring for wear or damage. Install a new blocking ring as necessary.





3. Remove the following components:
1 Remove the spacer.
2 Remove the thrust washer.
3 Remove the 3rd/4th gear synchronizer assembly.
4 Remove the 3rd gear synchronizer blocking ring.
^ Inspect all components for wear or damage. Install new components as necessary.





4. Remove the inner and outer 3rd gear synchronizer blocking rings.
^ Inspect the blocking rings for wear or damage. Install new blocking rings as necessary.





5. Remove 3rd gear.
^ Inspect the gear for wear or damage. Install a new gear as necessary.





6. Remove the 3rd gear needle bearing.
^ Inspect the bearing for wear or damage. Install a new bearing as necessary.





7. Place the shaft on a press, with the output end facing upward. Using the special tool, remove the output shaft bearing.
^ Inspect the bearing for wear or damage. Install a new bearing as necessary.





8. Remove the sleeve and 1st gear.
^ Inspect 1st gear for wear or damage. Install a new gear as necessary.





9. Remove the 1st gear needle bearing.
^ Inspect 1st gear for wear or damage. Install a new gear as necessary.





10. Remove the following components:
1 Remove the 1st gear synchronizer blocking ring.
2 Remove the outer synchronizer blocking ring.
3 Remove the inner synchronizer blocking ring.
^ Inspect the blocking rings for wear or damage. Install new blocking rings as necessary.





11. Remove the 1st/2nd gear synchronizer assembly and the 2nd gear synchronizer blocking ring.





12. Remove the inner and outer 2nd gear synchronizer blocking rings.
^ Inspect the blocking rings for wear or damage. Install new blocking rings as necessary.





13. Remove 2nd gear.





14. Remove the 2nd gear needle bearing.





15. Using the special tool, check the output shaft runout.
^ Check the runout in several places along the output shaft. If runout exceeds specification, install a new output shaft.





16. Check the clearance between the synchronizer blocking rings and the gear clutching teeth.
^ Place the synchronizer blocking ring on the gear. Insert a feeler gauge and measure the clearance, while applying pressure and rotating the ring. The clearance should be the same around the entire circumference.
- If the clearance is less than 0.8 mm (0.03 inch), install a new blocking ring or gear as necessary.





Assembly
1. Lubricate all output shaft components with the recommended lubricant during reassembly.
2. Install the 2nd gear needle bearing.





3. Install 2nd gear.





4. Install the inner and outer 2nd gear synchronizer blocking rings.
^ Align the tabs on the outer blocking ring with the notches in the gear.





5. Install the 2nd gear synchronizer blocking ring and the 1st/2nd gear synchronizer assembly.
^ Align the tabs on the inner blocking ring with the spaces on the 2nd gear synchronizer blocking ring.





6. Install the following components:
1 Install the 1st gear synchronizer blocking ring.
2 Install the outer synchronizer blocking ring.
3 Install the inner synchronizer blocking ring.
^ Align the tabs on the inner blocking ring with the spaces on the 2nd gear synchronizer blocking ring.





7. Install the 1st gear needle bearing.





8. Install 1st gear and the sleeve.
^ Align the tabs on the outer blocking ring with the notches in the gear.





9. CAUTION: Press the output shaft center bearing onto the shaft by the inner race only. Pressing on the outer race will damage the bearing.

Using the special tools, install the output shaft bearing.
^ Make sure the bearing is installed against 1st gear.





10. NOTE: Rotate the shaft so the output end is facing downward

Install the 3rd gear needle bearing.





11. Install 3rd gear.





12. Install the inner and outer 3rd gear synchronizer blocking rings.
^ Align the tabs on the outer blocking ring with the notches in the gear.





13. Install the following components:
^ 3rd gear synchronizer blocking ring
- Align the tabs on the inner blocking ring with the spaces on the 3rd gear synchronizer blocking ring.
^ 3rd/4th gear synchronizer assembly
^ Spacer
^ Thrust washer

14. Install the 4th gear synchronizer blocking ring and the snap ring.
^ Inspect the blocking ring for wear or damage. Install a new blocking ring as necessary.





15. Using a feeler gauge, check the 3rd/4th synchronizer hub end play.
^ If the clearance is not within specifications, select the correct snap ring.
^ Available snap ring sizes:
- 1.50 mm (0.05 inch)
- 1.55 mm (0.06 inch)
- 1.60 mm (0.06 inch)
- 1.65 mm (0.06 inch)
- 1.70 mm (0.06 inch)
- 1.75 mm (0.06 inch)
- 1.80 mm (0.07 inch)
- 1.85 mm (0.07 inch)
- 1.90 mm (0.07 inch)
- 1.95 mm (0.07 inch)





16. Install the input shaft needle bearing.