Output Shaft: Service and Repair

DISASSEMBLE
1. Remove pilot bearing, retaining ring, spacer, and needle bearing from front of output shaft.
2. Position front of output shaft so that it faces upward, then remove third/fourth clutch hub and sleeve.
3. Remove third gear synchronizer blocker ring.
4. Remove third gear.
5. Remove needle bearing.
6. Position output shaft with rear end (long side of flange) facing upward. Place output shaft into press with press cradle contacting lower part of second gear.

CAUTION: Ensure that output shaft flange does not contact or ride up onto press cradle, as improper positioning of output shaft can cause component damage.

Output Shaft Disassemble:

7. Press off center bearing, first gear sleeve, first gear needle bearing, first gear, first gear synchronizer blocker ring, first/second clutch hub and sleeve assembly, second gear synchronizer blocker ring, second gear, and second gear needle bearing.

INSPECTION

Output Shaft Runout Measurement:

1. Check output shaft for runout by mounting the shaft between V blocks and applying a dial indicator to several places along shaft. If runout exceeds 0.002 inch, replace output shaft.
2. Replace input shaft if splines are damaged, needle bearing surface in bore of bearing is worn, or rough or cone surface is damaged.

ASSEMBLE

NOTE:Lubricate all rotating and sliding components with Dexron-II or equivalent during assembly.

Output Shaft Assembly:

1. Position output shaft so rear end faces upward. Lubricate all bearing journals. Install the following parts in the order listed, using bearing replacer tool No. T53T-4621-B and bearing plate tool No. T75L-1165-B or equivalent.
a. Second gear needle bearing.
b. Second gear.
c. Second gear synchronizer blocker ring, aligning ring with synchronizer insert keys.
d. First/second clutch hub and sleeve assembly. Ensure smaller width of sleeve faces second gear side and reference mark for installation faces rear of transmission.
e. First gear synchronizer blocker ring, aligning ring with synchronizer insert keys.
f. First gear needle bearing to first gear sleeve.
g. First gear.
h. First gear sleeve and needle bearing assembly.
i. Center bearing. Ensure bearing is installed completely onto output shaft.
2. Position output shaft so front of output shaft flange faces upward, then install the following components:
a. Third gear needle bearing.
b. Third gear.
c. Third gear synchronizer blocker ring.
3. Install third/fourth clutch hub and sleeve as follows:
a. Mate clutch hub synchronizer key groove with reference mark on the clutch hub sleeve. Reference mark should face rearward.
b. Install longer flange on clutch hub sleeve, toward third gear (rear) side. The front and rear sides of the clutch sleeve are the same except for the reference mark on one side.
4. Install spacer, needle bearing, rollers upward, retaining ring.
5. Install original retaining ring. Check clutch hub endplay using a feeler gauge.

Retaining Ring Selection Chart:

6. If necessary, adjust third/fourth clutch hub endplay to 0.0000-0.0019 inch by selecting required retaining ring.