Output Shaft Disassembly/Assembly

OUTPUT SHAFT DISASSEMBLY/ASSEMBLY

Output Shaft:

Disassembly





1. Prior to disassembly of the main shaft, measure and record end play for 1st and 2nd gears.
2. Remove and discard the snap ring.
3. Remove the C-ring holder.
4. Remove the mainshaft C-ring.
5. Using the special tool, remove the mainshaft rear bearing.





6. Remove and discard the snap ring.
7. Using the special tool, remove the 5th main gear and the 4th main gear together.
^ Discard both gears.





8. Remove the 4th gear main adjusting shim.
9. Remove the 3rd/4th gear shaft spacer.





10. Remove the 3rd main gear, 2nd main gear, 2nd gear needle bearing, 2nd gear bushing, 1st and 2nd gear synchronizer assembly, 1st and 2nd gear synchronizer rings, 1st main gear, reverse main gear, 1st gear needle bearing and 1st gear bushing together.
^ Discard the 3rd main gear, the reverse main gear, and the 1st and 2nd gear synchronizer assembly.





11. Inspect all mainshaft parts for damage, peeling, dents, uneven wear or bending. Install new parts as necessary.
12. Inspect the synchronizer rings for damage. Install new parts as necessary.








13. Check the clearances of the double cone synchronizer for 1st gear. If any of the clearances are beyond specification, install new parts as a set.

Note
^ The outer synchronizer ring, synchronizer cone and inner synchronizer ring have a set control clearance. If the measurement exceeds specification, install all 3 parts as a set.





14. Using the special tool, measure the clearance at 2 or more points diagonally between the synchronizer cone and the inner synchronizer ring. Install new parts if not within specification.

Note
^ If the difference in measurements is greater than 0.2 mm (0.078 in), install new parts.





15. Measure the clearance between the outer synchronizer ring and the synchronizer cone at 2 or more points diagonally opposite and calculate the mean value. Install new parts if not within specification.

Note
^ If the difference in measurements is greater than 0.2 mm (0.078 in), install new parts.

16. Check the clearances of the triple cone synchronizer for 2nd gear. If any of the clearances are beyond specification, install new parts as a set.

Caution
^ The outer synchronizer ring, synchronizer cone and inner synchronizer ring have a set control clearance. If the measurement exceeds specification, install all 3 parts new as a set.





17. Measure the clearance at 2 or more points diagonally opposite and calculate the mean. If the measurement is not within specification, install new parts.

Note
^ If the difference in measurements is greater than 0.3 mm (0.01 in), install new parts.





18. Measure the clearance at 2 or more points diagonally opposite and calculate the mean. If the measurement is not within specification, install new parts.

Note
^ If the difference in measurements is greater than 0.17 mm (0.007 in) install new parts.





19. Measure the clearance at 2 or more points diagonally opposite and calculate the mean. If the measurement is not within specification, install new parts.

Note
^ If the difference in measurements is greater than 0.3 mm (0.01 in), install new parts.

Assembly





1. Position the reverse main gear on the mainshaft.

Caution
^ Be careful with the orientation of the reverse main gear.





2. Using the special tool, install a new reverse main gear.
3. Install the 1st main gear.





4. Using the special tools, install the 1st main gear bushing.
5. Install the 1st gear needle bearing.
6. Install the 1st gear synchronizer ring.





7. Position a new 1st and 2nd gear synchronizer assembly on the mainshaft.

Caution
^ Make sure the synchronizer side with 3 notches is facing 1st gear and the synchronizer side with 4 notches is facing 2nd gear.





8. Using the special tools, install the 1st and 2nd gear synchronizer assembly.





9. Install the 2nd gear synchronizer ring.





10. Using the special tools, install the 2nd gear bushing.
11. Install the 2nd gear needle bearing.
12. Install the 2nd main gear.





13. Using the special tools, install a new 3rd main gear.

Caution
^ Be careful with the orientation of the 3rd main gear.





14. Install the 3rd/4th main gear shaft spacer.





15. Measure the mainshaft components as indicated to select the appropriate 4th main gear adjusting shim. See the table for shim thicknesses and install the 4th main gear adjusting shim.

Caution
^ Only one adjusting shim can be installed.





16. Using the special tool, install a new 4th main gear.

Caution
^ Be careful with the orientation of the 4th main gear.





17. Using the special tool, install a new 5th main gear.

Caution
^ Be careful with the orientation of the 5th main gear.





18. Measure the gap between the snap ring and the 5th main gear. The end play should be less than 0.1 mm (0.0039 in). See the chart to select the appropriate snap ring thickness and install a new snap ring.





19. Using the special tool, install the mainshaft rear bearing.

Caution
^ Be careful with the orientation of the mainshaft rear bearing.





20. Measure the gap between the mainshaft C-ring and the mainshaft rear bearing. See the chart to select the appropriate C-ring thickness and install the C-ring.
21. Install the C-ring holder.
22. Install a new snap ring.