Disassembly

1. Use a feeler gauge to measure the clearance between the third gear (3GR) and the second gear.
2. The clearance should measure 0.05-0.20 mm (0.002-0.007 inch) with a maximum of 0.25 mm (0.010 inch).
3. If the clearance exceeds the maximum, check the contact surfaces of the gears and the synchronizer.
4. Replace all worn or damaged parts.
5. Use a feeler gauge to measure the clearance between the fourth gear (4GR) and the bearing (fourth gear end).
6. The clearance should measure 0.17-0.37 mm (0.007-0.015 inch) with a maximum of 0.42 mm (0.017 inch).
7. If the clearance exceeds the maximum, check the contact surfaces of the fourth gear, the bearing, and the synchronizer hub.
8. Replace all worn or damaged parts.





9. Use a Rotunda 25-Ton Capacity General Purpose Press 014-00085 and Bearing Pulling Attachment D84L-1123-A or equivalent to remove the bearing (fourth gear end).

CAUTION: Hold the input shaft with one hand so that it does not fall.

10. Remove the fourth gear from the input shaft.
11. Remove the synchronizer blocking ring.
12. Remove the snap ring.
13. Slide the synchronizer from the input shaft.
14. Remove the synchronizer blocking ring.





15. Use the hydraulic press and Bearing Pulling Attachment D84L-1123-A or equivalent to remove the third gear from the input shaft.

CAUTION: Hold the input shaft with one hand so that it does not fall.





16. Use Bearing Pulling Attachment D84L-1123-A and Shaft Protector D80L-625-4 or equivalent to remove the bearing (first gear end) from the input shaft.

CAUTION: Hold the input shaft with one hand so that it does not fall.

17. Clean and inspect the components for excessive wear.