Output Shaft Geartrain Assembly
Assembly - Output Shaft GeartrainNOTE: If any output shaft gear is replaced, the countershaft gear must also be replaced to maintain the proper gear mesh and prevent noisy operation.
Coat the output shaft and gear bores with transmission lubricant.
Install and align the first-second gear synchronizer sleeve on the output shaft hub using the reference marks scribed during disassembly.
Install the 3 first-second gear synchronizer inserts (50) and the 2 insert springs (51) in the first-reverse gear synchronizer sleeve. Engage the tang of each insert spring in the same synchronizer insert but position the open ends of the springs to face 180 degrees (opposite) from each other. Ensure that the sleeve and hub reference marks are aligned.
Install the blocking ring and second gear (41) on the output shaft.
Install the tabbed thrust washer (40) and second gear retaining snap ring (39) on the output shaft.
Ensure that the washer tab is properly seated in the output shaft.
Install the blocking ring and first gear on the output shaft.
Install the first gear roll pin (A) in the output shaft. Install the first gear thrust washer (42).
Press the rear bearing on the output shaft with Tool J-6133-0i.
Install the third gear on the output shaft. Install the third-fourth gear blocking ring on the third gear.
Align the reference scribe marks on the third- fourth gear synchronizer hub and sleeve (38) and the output shaft. Start the hub on the output shaft. Press the hub and sleeve on the output shaft (until seated) with an arbor press.
NOTE: Ensure that the blocking ring is aligned with the synchronizer sleeve before seating the hub and sleeve.
Install the fourth gear blocking ring in the third-fourth gear synchronizer sleeve.
Install the thrust bearing washer on the forward end of the output shaft.