Output Shaft

DISASSEMBLE
1. Install suitable holder under first driven gear, then use suitable press to remove fifth driven gear bearing, bearing race and thrust washer. Synchronizer hub and sleeves must be kept together as a matched set. Note spline alignment marks on hub and sleeve.

2. Remove output shaft ball bearing.

3. Remove third/fourth driven gear, then the second driven gear and bearing.

4. Remove second driven gear bearing race and blocker ring.

5. Remove 1-2 synchronizer sleeve and hub.

6. Remove first gear blocker ring, then the first driven gear, bearing and thrust washer.


ASSEMBLE
Lubricate all rotating parts and bearings with ATF-Dexron II or equivalent, during assembly. Soak blocker ring in ATF-Dexron II, or equivalent, for 15 minutes prior to installation.

1. Install first driven gear thrust bearing with black side down.

2. Install first driven gear bearing, then driven gear.

3. Install first gear synchronizer blocker ring and synchronizer spring.

4. Press first/second synchronizer hub onto shaft, aligning tangs on blocker ring with slots in hub.

5. Install 1-2 synchronizer sleeve, with reverse driven gear facing down toward first gear.

6. Install second gear synchronizer spring on second gear synchronizer blocker ring, then install assembly.

7. Install second gear bearing race. Warm bearing with hands or heat gun to ease installation.

8. Install second gear bearing, then the driven gear.

9. Install third/fourth driven gear with third gear on bottom.

10. Press output shaft (ball) bearing onto shaft with snap ring groove facing up and away from gears.