Assembly

1. Use a Rotunda 25-Ton capacity General Purpose Press 014-00085 or equivalent and adapter (Part of Rotunda 25-Ton Press Accessory Set 014-00131) to install the bearing (first gear end).
2. Install the first gear.
3. Install the synchronizer blocking ring.








NOTE:
^ The first, second, third, and fourth synchronizer blocking rings are the same dimensions, but the second synchronizer blocking ring has a cutout as shown.
^ When installing the synchronizer blocking ring and reverse gear, align the synchronizer blocking ring groove and synchronizer hub insert.





4. Install the synchronizer.

NOTE: Face the oil groove away from the first gear.

5. Install the snap ring.
6. Install the synchronizer blocking ring.
7. Install the second gear.





8. Use the hydraulic press, Shaft Protector D80L-625-4 or equivalent, and Axle Bearing to Seal Plate T75L-1165-B to install the third gear as shown.
9. Install the snap ring.





10. Use the hydraulic press and Axle Bearing/Seal Plate T75L-1165-B to install the fourth gear and the bearing (fourth gear end) as shown.





11. Measure the clearance between the first gear and the differential drive gear with a feeler gauge.
12. The clearance should measure 0.05-0.28 mm (0.002-0.011 inch), with a maximum of 0.33 mm (0.013 inch).
13. If the clearance is not within specifications, reassemble the output shaft.





14. Measure the clearance between the second gear and the third gear with a feeler gauge.
15. The clearance should measure 0.18-0.46 mm (0.007-0.018 inch), with a maximum of 0.51 mm (0.020 inch)
16. If the clearances are not within specifications, reassemble the output shaft