Disassembly

Removing Third/Fourth Synchronizer:

1. Remove third-fourth synchronizer, third speed blocking ring, and third gear as an assembly, using universal press plate tool No. D&9L-4621-A and suitable press.
2. Remove needle bearing assembly and spacer from output shaft.
3. Remove fifth gear snap ring, then fifth gear, using press plate.
4. Remove output shaft rear bearing and first gear.
5. Remove needle bearing assembly and sleeve. Sleeve is snugly fit onto output shaft.
6. Remove roll pin using a pencil magnet.
7. Remove first gear blocker ring assembly from output shaft, then second gear snap ring and thrust washer.
8. Remove second gear, second gear needle bearings and spacer from output shaft.
9. Disengage spiral snap ring from slot in output shaft using a small screwdriver, then remove thrust washer.
10. Remove second gear blocker ring assembly, then first-second synchronizer from output shaft.
11. Remove detent ball and spring from hub on output shaft. The first and second speed synchronizer and hub is serviced only as an assembly with the output shaft. No attempt should be made to separate the hub from the shaft.
12. The sleeve, springs and inserts may be removed from the hub after scratching or etching alignment marks on the hub and sleeve. If hub or sleeve is worn or damaged, the shaft and synchronizer must be replaced as an assembly.