Disassembly

1. 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.





2. Remove bearing as an assembly and third speed gear bearing spacer from output and fifth gear drive shaft.





3. Remove fifth speed gear snap ring.





4. Using a press and Bearing Pulling Attachment D79L-46211-A or equivalent, remove fifth speed gear.





5. Remove output shaft rear bearing.





6. Remove first gear.





7. Remove output and fifth gear drive shaft as an assembly and input bearing spacer.

NOTE: There is a snug fit between the input bearing spacer and the output and fifth gear drive shaft.





8. Remove first and second speed synchronizer hub pin using a pencil magnet.





9. Remove first and second gear synchronizer inner cone, first and second gear synchronizer outer cone and synchronizer blocking ring as an assembly from output and fifth gear drive shaft.





10. Remove second gear snap ring and thrust washer.





11. Remove second gear from output and fifth gear drive shaft.





12. Remove bearing assembly and second speed gear bearing spacer.





13. Disengage output shaft bearing to case snap ring from slot in output and fifth gear drive shaft using a small screwdriver.





14. Remove output shaft bearing to case snap ring and first and second speed synchronizer thrust washer from output and fifth gear drive shaft.
15. Remove first and second gear synchronizer inner cone, first and second gear synchronizer outer cone and synchronizer blocking ring as an assembly.





16. Remove first/second synchronizer from output and fifth gear drive shaft.





17. The synchronizer blocking spring and synchronizer hub inserts may be removed from the hub after scratching or etching alignment marks on the hub and synchronizer. The only parts that can be serviced are the synchronizer blocking springs and synchronizer hub inserts. If the hub or sleeve is worn or damaged, the output and fifth gear drive shaft and synchronizer must be replaced as an assembly. Service and Repair

NOTE: The first/second speed synchronizer and hub is serviced only as an assembly with the output and fifth gear drive shaft. No attempt should be made to separate the hub from the output and fifth gear drive shaft.