Assembly

1. Install synchronizer hub inserts in first/second synchronizer hub on output and fifth gear drive shaft.





2. Install first/second synchronizer as an assembly, first and second gear synchronizer inner cone, first and second gear synchronizer outer cone and synchronizer blocking ring as an assembly onto output and fifth gear drive shaft.

NOTE: Align slots in synchronizer blocking ring with tabs in first/second synchronizer.





3. Install first and second speed synchronizer thrust washer onto output and fifth gear drive shaft. Install output shaft bearing to case snap ring using Spiral Snap Ring Replacer T85P-7025-A.





4. Install bearing and second speed gear bearing spacer.





5. Install second gear onto output and fifth gear drive shaft.

NOTE: Align slots in second gear with tabs on synchronizer blocking ring assembly.





6. Install thrust washer. Install second gear snap ring using snap ring pliers.





7. Install first and second gear synchronizer inner cone, first and second gear synchronizer outer cone and synchronizer blocking ring as an assembly onto output and fifth gear drive shaft.

NOTE: Align slot in first gear synchronizer blocking ring with tab on first/second synchronizer.





8. Drop first and second speed synchronizer hub pin into output and fifth gear drive shaft.

NOTE: Use pencil magnet if necessary.





9. While aligning notch in input bearing spacer with first and second speed synchronizer hub pin, slide input bearing spacer onto output and fifth gear drive shaft. Install needle bearing assembly over input bearing spacer.





10. Install first gear onto output and fifth gear drive shaft.

NOTE: Align slots in first gear with tabs on first gear synchronizer blocking ring as an assembly.





11. Install rear output shaft bearing onto output and fifth gear drive shaft. The bearing taper must face the rear of the output and fifth gear drive shaft.

CAUTION: Make sure the output and fifth gear drive shaft and first gear splines are carefully aligned. If splines are improperly aligned, damage could occur when the first gear is pressed onto the output and fifth gear drive shaft.





12. Lubricate fifth speed gear splines with petroleum jelly and position on output and fifth gear drive shaft. Using a press and a capped length of pipe, 31.75 mm inner diameter x 356 mm (1-1/4 inch inner diameter x 14 inch), press fifth speed gear onto output and fifth gear drive shaft.





13. Using snap ring pliers, install fifth speed gear snap ring.





14. Install third speed gear bearing spacer and bearing as an assembly onto output and fifth gear drive shaft.





15. Using a press and a 1-1/2 inch-deep well socket, install third/fourth synchronizer, synchronizer blocking ring and third gear as an assembly.

NOTE: Before pressing components together, make sure the synchronizer hub faces the short end of the output and fifth gear drive shaft. Hold third gear against the synchronizer to maintain synchronizer blocking ring alignment.