Output Shaft

DISASSEMBLE
A hydraulic press (15 ton force minimum), output shaft gear removal tool No. J-22912-01 and press tube tool No. J-36183, or equivalents, are necessary for the following procedure.

Identify blocker ring (31) for the fifth gear, blocker ring (41) for second gear and blocker ring (48) for first gear. Do not interchange blocker rings.

1. Remove reverse gear/fifth gear synchronizer assembly (25), using output shaft gear remover/ installer tool No. J-22912-01, or equivalent, and press.

2. Remove reverse gear/fifth gear synchronizer assembly (25) using split plate tool No. J-36513, or equivalent, and press.

3. Remove blocker ring (3).

4. Remove fifth gear (32) and fifth gear bearing (33).

5. Remove thrust washer (35) and ball (34).

6. Remove snap ring (36).

7. Remove first gear using split plate tool No. J-36513, or equivalent, and a hydraulic press. Second gear (38), bearing (39), race (40), 1-2 synchronizer (42), blocker rings (41 and 48) and 34 gear cluster (37) will press off with first gear.

8. Remove bearing (50) and thrust washer (52A).






INSPECTION
Inspect components for excessive wear and/or damage. Replace worn or damaged components as required.


ASSEMBLE
An oven, hydraulic press, press tube tool No. J-361 83 and press tube reducer tool No. J-36184, or equivalents, are required for this procedure.

Bearing race (40) requires heating to approximately 250°F in an oven. The third/fourth gear cluster (37) requires heating to approximately 250°F in an oven. This requires a minimum heating time of 20 minutes.

Lubricate all components with Synchromesh assembly lube part No. 12345349, or equivalent.

1. Install thrust washer (52) with chamfer facing downward, then the caged thrust bearing (51) with needles facing downward.

2. On all models, install first gear bearing (50) and first gear (49) with cone facing upward.

3. Install blocker ring (48).

4. Using hydraulic press, press tube tool No. J-36183 and press tube reducer tool No. J-361 84, or equivalents, install 1-2 synchronizer assembly (42), noting the following:

a. Ensure side marked "first" and small outside diameter groove on sleeve faces toward first gear.

b. Stop press operation before tangs engage.

c. Lift and rotate gears (49) and (48), to engage blocker ring tangs.

d. Continue to press until seated.

e. Ensure all shavings are removed.

5. Install second gear bearing race (40), bearing (39) and second gear (38) with cone facing downward.

6. Install third/fourth gear cluster (37) using press tube tool, tube reducer tube and press. Ensure large outside diameter gear faces downward.

7. Install new snap ring (36), thrust washer ball (34), retained with petroleum jelly, and slotted thrust washer (35). Ensure inside diameter slot is aligned with ball (34).

8. Install fifth gear bearing (33) and fifth gear (32).

9. Install blocker ring (31).

10. Install reverse gear and fifth synchronizer (25), noting the following:

a. Stop press operation before tangs engage.

b. Lift and rotate fifth gear (32) and blocker ring (31), engaging tangs.
Thrust washer (35) must stay down.

c. Press until seated, then ensure & shavings are removed.