Assembly

1. Install detent ball and spring in first-second synchronizer hub on output shaft.

Installing First-Second Synchronizer Assembly:

2. Install first-second synchronizer assembly, and second gear blocker ring assembly onto output shaft. Align slots in blocker ring with tabs in first-second synchronizer.
3. Install thrust washer onto output shaft, then spiral snap ring.
4. Install second gear needle bearing, spacer and second gear onto output shaft. Align slots in second gear with tabs on blocker ring assembly.
5. Install second gear thrust washer and snap ring.
6. Install first gear blocker ring assembly onto output shaft. Align slot in first gear blocking ring with tab on first-second synchronizer.
7. Install roll pin into output shaft.
8. While aligning notch in sleeve with roll pin, slide sleeve onto output shaft, then install needle bearing assembly over sleeve.
9. Install first gear onto output shaft. Align slots in first gear with tabs on first gear blocking ring assembly.
10. Install rear output shaft bearing onto output shaft. Bearing taper must face rear of the shaft.
11. Lubricate fifth gear splines with petroleum jelly, then install fifth gear on output shaft. Using a press and a capped piece of pipe (1 1/4x14 inches) press fifth gear onto output shaft. Ensure output shaft and gear splines are aligned. Damage can occur if not aligned properly prior to pressing gear onto output shaft.
12. Using snap ring pliers, install fifth gear snap ring, then install spacer and split needle bearing assembly onto output shaft.
13. Using a press and a 1 1/2 inch deep well socket, install third-fourth synchronizer, third blocking ring and third gear as an assembly. Ensure synchronizer hub faces the short end of the output shaft. Hold the third gear against the synchronizer to maintain blocking ring alignment.