Output Shaft

Output Shaft





Special Tool(s)

Disassembly





1. Remove the retaining ring above fifth gear.





2. CAUTION: Hand tighten the special tool to prevent gear damage.

CAUTION: Support the output shaft while using the press to prevent damage to the shaft or gears.

Using the special tool, press fifth gear, the spacer, the output shaft bearing and reverse gear from the output shaft.
- Discard the output shaft bearing.





3. Remove reverse gear needle bearing.
- Inspect the needle bearing for wear or damage. Install a new needle bearing as necessary.





4. Remove the check ball and the blocking ring.
- Inspect the blocking ring for wear or damage. Install new blocking rings as necessary.





5. NOTE: Install the special tool with the flat side facing first gear.

Using the special tools, press the bearing spacer, the reverse gear synchronizer cone and first gear from the output shaft.





6. Remove the first gear needle bearing.
- Inspect the needle bearing for wear or damage. Install a new needle bearing as necessary.





7. Remove the first gear synchronizer inner cone, the first gear synchronizer outer cone and the first gear synchronizer blocking ring.
- Inspect all components for wear or damage.
- Install new components as necessary.





8. NOTE: Reposition the output shaft on the press with the input shaft end facing upward.

Remove and discard the retaining ring.





9. Remove the third/fourth synchronizer hub.





10. Remove the third/fourth blocking ring.





11. Remove the third gear.
- Inspect the gear for wear or damage. Install a new gear as necessary.





12. Remove the third gear needle bearing.
- Inspect the needle bearing for wear or damage. Install a new needle bearing as necessary.





13. NOTE: Install the special tool behind second gear with the flat side of the tool facing second gear.

Using the special tool, remove the spacer, second gear thrust washer and second gear.
- Inspect the gear for wear or damage. Install a new gear as necessary.





14. Remove the check ball and second gear needle bearing.
- Inspect the needle bearing for wear or damage. Install a new needle bearing as necessary.





15. Remove the second gear synchronizer inner cone, second gear synchronizer outer cone and the second gear synchronizer blocking ring.
- Inspect all components for wear or damage. Install new components as necessary.





16. Remove the snap ring, then using the special tool, press off the first/second gear synchronizer.

Assembly
1. Carry out the following before reassembling:
- Inspect the gears for broken or cracked teeth.
- Check for unusual wear patterns.
- Inspect the thrust washers for face wear, cracks, scoring and for signs of heat damage.
- Inspect the bearings, bearing cups and the synchronizers for wear or damage.
- Inspect the output shaft for scoring or worn or damaged splines. Install new components as necessary.
2. Lubricate all components with the recommended transmission fluid when reassembling.








3. NOTE: Position the output shaft with the output end facing upward.

NOTE: Install the synchronizer assembly with the deeper center flange of the synchronizer hub facing toward the rear of the output shaft.

Install the first/second synchronizer assembly on the output shaft, then install a new retaining ring.
- It may be necessary to press the hub into position on the shaft.





4. Install the first gear synchronizer blocking ring.
- Align the blocking ring tabs with the synchronizer assembly.





5. Install the outer first gear synchronizer cone.





6. Install the inner first gear synchronizer cone.
- Rotate the inner cone till it is seated.





7. Install the first gear needle bearing.
- Apply petroleum jelly to the bearing.





8. Install first gear.
- Rotate the gear to align the gear slots with the inner cone tabs.





9. Install the reverse synchronizer cone.





10. Install the reverse gear blocking ring.





11. Using the special tools, install the reverse gear bearing spacer.





12. Install reverse gear needle bearing. Apply petroleum jelly to the bearing.





13. Install reverse gear. Rotate the gear to align the gear slots with the inner cone tabs.





14. Install the check ball. Use petroleum jelly to hold the check ball in place.





15. Install the thrust washer. Be sure to align the slot in the washer with the check ball.





16. Install a new rear output shaft bearing, then fifth gear. Using the special tool, press both the bearing and gear into place.
17. Reposition the output shaft with the input end facing upward.





18. Install the second gear synchronizer blocking ring.
- Rotate the blocking ring until seated.





19. Install the second gear synchronizer outer cone and the second gear synchronizer inner cone.





20. Install the second gear bearing.
- Apply petroleum jelly to the bearing.





21. Install second gear.
- Rotate the gear to align the gear slots with the inner cone tabs.





22. Install the check ball.
- Use petroleum jelly to hold the check ball in place.





23. Install the thrust washer. Be sure to align the slot in the washer with the check ball.





24. Press the bearing spacer onto the output shaft.





25. Install the third gear bearing.
- Apply petroleum jelly to the bearing.





26. Install third gear.





27. Install the third gear synchronizer blocking ring.





28. Install the third/fourth gear synchronizer body.
- Install the synchronizer body with the raised center facing downward.
- Rotate the blocking ring until seated.





29. Install a new retaining ring.