Input Shaft: Service and Repair

Exploded View Of Input Shaft:

1. Press off bearing cone from 4th gear end using shaft protector D80L-625-4 and bearing pulling attachment-D84L-1123-A or equivalents.
2. Remove 4th gear, synchronizer ring and retaining ring.
3. Press off the clutch hub assembly and synchronizer ring, then 3rd gear using shaft protector D80L-625-4 and puller plate T71P-4621-B or equivalents.
4. Press off bearing cone from 3rd gear end using shaft protector D80L-625-A and bearing pulling attachment D84L-1123-A or equivalents.
5. Install clutch hub into clutch hub sleeve, then the synchronizer keys and springs.
6. Press bearing cone onto 3rd gear end using shaft protector D80L-625-6, bearing cone replacer T88C-7025-DH and bearing cone installing plate T75L-1165-B or equivalents. Whenever a bearing cone is removed, it must be replaced.

Synchronizer Ring Groove And Synchronizer Key Alignment:

7. Press 3rd gear, synchronizer ring and clutch hub assembly on shaft, using shaft protector D80L-625-6, bearing installing plate T75L-1165-B and bearing cone replacer T87C-77000-D or equivalents, then installing synchronizer ring and clutch hub assembly, align synchronizer ring groove and synchronizer key. Ensure clutch hub assembly ridge is facing 3rd gear.
8. Install retaining ring, synchronizer ring, 4th gear and bearing cone, using shaft protector D80L-625-6, bearing cone installing plate T75L-1165-B and bearing cone replacer T88C-7025-D or equivalents.