Output Shaft and Bearing
Output Shaft and BearingSpecial Tool(s):
Disassembly
1. Remove these components:
1 The bearing outer snap ring.
2 The third/fourth synchronizer spacer.
3 The thrust bearing.
2. NOTE: Press off 3rd/4th synchronizer, if stuck.
Remove these components:
1 The 3rd/4th synchronizer.
2 The 3rd gear blocking ring.
3 The 3rd gear.
4 The 3rd gear needle bearing.
3. CAUTION: Make sure that the output shaft flange does not contact or ride up onto the press cradle. Incorrect positioning can result in component damage.
Position the output shaft in a press. Press off the output shaft center bearing, the 1st gear, the 1st/2nd synchronizer assembly and the 2nd gear.
Assembly
1. Using the special tool, check the output shaft runout.
^ Check runout in several places along the output shaft. If runout exceeds 0.05 mm (0.002 inch) install a new output shaft.
2. Identify the synchronizer blocking ring.
1 First gear synchronizer blocking ring (R1 model)
2 First gear synchronizer blocking ring (R1 HD model)
3 Second and 4th gear synchronizer ring (R1 and R1 HD models)
3. Inspect the synchronizer blocking rings for correct contact with the cone surface of 1st gear.
4. Inspect the synchronizer blocking rings for wear on 2nd gear.
^ Vehicles equipped with 2.3L and 3.0L engines have dual cone blocking rings. Measure both blocking rings.
^ If clearance is less than specification, install a new blocking ring or gear.
5. Assemble the 1st and 2nd gear assembly as follows.
1 Install the 2nd gear needle bearing.
2 Install the 2nd gear.
3 Install the 2nd synchronizer blocking ring.
^ Vehicles equipped with 2.3L and 3.0L engines have a dual cone blocking ring.
4 Install the 1st gear synchronizer blocking ring.
5 Install the 1st gear.
6 Install the 1st gear needle bearing.
7 Install the input bearing spacer.
8 Position the output shaft center bearing.
6. Using the special tools, press the output shaft center bearing into place.
7. NOTE: If necessary, use press to install the 3rd/4th synchronizer.
Install these components:
1 The 3rd gear needle bearing.
2 The 3rd gear.
3 The 3rd gear blocking ring.
4 The 3rd/4th synchronizer.
8. Install these components:
1 The thrust bearing.
2 The 3rd/4th synchronizer spacer.
3 The bearing outer snap ring.
9. Check the 3rd/4th clutch hub end play.
^ If clearance is not within specification, select the correct bearing outer snap ring.
Bearing Outer Snap Ring Select Chart:
