Assembly

1. Use a Rotunda 25-Ton Capacity General Purpose Press 014-00085, Shaft Protector D80L-625-4, and Bearing Pulling Attachment D84L-1123-A or equivalents to install the new bearing (first gear end).
2. Use the hydraulic press and Bearing Pulling Attachment D84L-1123-A or equivalent to install the third gear.
3. Slide the synchronizer blocking ring onto the input shaft.

NOTE: Ensure that the toothed side of the synchronizer blocking ring is facing away from the synchronizer.

4. Slide the synchronizer onto the input shaft.

NOTE: Ensure that the synchronizer is installed properly on the input shaft.

5. Snap the snap ring into place.

NOTE: Ensure that the snap ring is fully seated in the input shaft groove.

6. Install the synchronizer blocking ring.

NOTE: Ensure that the toothed side of the synchronizer blocking ring is facing away from the synchronizer.





7. Use the hydraulic press, Shaft Protector D80L-625-4 or equivalent, and Axle Bearing/Seal Plate T75L-1165-B to install the fourth gear and a new bearing (fourth gear end).





8. Measure the clearance between the third gear and the second gear with a feeler gauge.
9. If the clearance does not measure 0.05-0.20 mm (0.002-0.007 inch) with a maximum of 0.25 mm (0.010 inch), reassemble the input shaft.





10. Measure the clearance between the fourth gear and the bearing (fourth gear end).
11. If the clearance does not measure 0.17-0.37 mm (0.007-0.015 inch) with a maximum of 0.42 mm (0.017 inch), reassemble the input shaft assembly.