Mainshaft Assembly

- Tools Required:
- Hydraulic Press
- J 36183 Input Shaft Press Tube with Cap
- J 36184 Adapter Press Tube Reducer
- J 39924-1 Reverse Drag Seal Installer
- J 39924-2 Fifth Gear Drag Seal Installer

ASSEMBLE

Important
- The assembly of some components will require use of an assembly lube. It is recommended that TRANSJEL (tm) J 36850 or equivalent be used during assembly.
- Heat the 2WD speed sensor rotor for 7-10 minutes at 120°C (250° F) prior to installation during assembly procedures.





1. Fifth gear drag seal onto the mainshaft using J 39924-2.





2. Reverse gear drag seal onto the reverse gear using J 39924-1.





3. Bearing assembly and reverse speed gear.
4. When pressing the fifth-reverse synchronizer assembly:
A. Manually align and engage splines.
B. Press until seated.
C. Be sure all shavings are removed.
5. Fifth-reverse synchronizer assembly with synchronizer ring using J 36183 and J 36184 and a hydraulic press.
- Check scribe marks for correct positions.
- Position spiral lock ring towards reverse speed gear.
6. NEW snap ring.





7. Bearing assembly and fifth speed gear.





8. Bearing assembly and first speed gear.
9. Synchronizer interim ring, reaction cone, blocker ring and synchronizer cone.
10. When pressing the first-second synchronizer assembly:
A. Manually align and engage splines.
B. Start press operation, STOP before tangs engage.
C. Lift and rotate gear to engage synchronizer ring.
D. Continue to press until seated.
E. Be sure all shavings are removed.
11. First-second synchronizer assembly with both synchronizer rings using J 36183 and J 36184 and a hydraulic press.
- Check scribe marks for correct positions.

Important
- The groove on the outside of the sleeve MUST GO TOWARDS THE SECOND SPEED GEAR to prevent gear clash during first and second gear shifts. The teeth of the sleeve have different angles.

12. Snap ring.





13. Synchronizer cone, blocker ring, reaction cone and interim ring.
14. Bearing assembly and second speed gear.
- Make sure bearing cage is together.
15. Spacers and collar.
- Install spacers with the locating dots facing up.





16. Bearing assembly and third speed gear.
17. When pressing the third-fourth synchronizer assembly:
A. Manually align and engage splines.
B. Start press operation, STOP before tangs engage.
C. Lift and rotate gear, to engage synchronizer rings
D. Continue to press until seated.
E. Be sure all shavings are removed.
18. Third-fourth synchronizer assembly with both synchronizer rings using J 36183 and J 36184 and a hydraulic press.
19. NEW snap ring.