Disassembly

NOTE: The following procedure should be performed only when necessary. After carefully inspecting each subassembly, disassemble only those requiring component replacement or further inspection.

DISASSEMBLY
1. Remove main gearshift rail and gearshift forks from output shaft.





2. Remove third-fourth synchronizer hub retaining ring from front of output shaft.





3. Install Bearing Pulling Attachment D79L-4621-A or equivalent between second speed gear and third speed gear with flat side of puller toward third speed gear as shown.

CAUTION: Only hand-tighten bearing puller to prevent damage to gear.





4. Using a press and Bearing Pulling Attachment D79L-4621-A or equivalent, remove third/fourth synchronizer, third speed synchronizer blocking ring, and third gear as an assembly.

CAUTION: Support output shaft while using press to prevent damage if dropped.





5. Remove bearing assembly and third speed gear bearing spacer from output and fifth gear drive shaft.





6. Install Bearing Pulling Attachment D79L-4621-A or equivalent on forward side of first speed gear with flat side of puller toward gear as shown.

CAUTION: Only hand-tighten puller to prevent damage to gear.





7. Using a press and Bearing Pulling Attachment D79L-4621-A or equivalent, remove fifth speed gear, tapered roller bearing and first speed gear. Discard tapered roller bearing.

CAUTION: Support output shaft while using press to prevent damage if dropped.

8. Remove first gear needle bearing.





9. Remove retaining ring from rear of first-second synchronizer.





10. Remove the first-second synchronizer thrust washer, inner synchronizer cone, synchronizer middle blocker ring and outer blocker ring.





11. Place Bearing Pulling Attachment D79L-4621-A or equivalent behind second gear. Using press, remove first-second synchronizer assembly from hub.

CAUTION:
^ Do not press on output shaft thrust flange.
^ Support output shaft while using press to prevent damage if dropped.





12. Remove first-second synchronizer assembly, second gear and needle bearing from output and fifth gear drive shaft.

NOTE: Identify parts for reassembly.





13. Using Bearing Puller Attachment D79L-4621-A or equivalent and press, remove input shaft pocket support bearing.