Disassembly

1. Measure the clearance between the first gear (1GR) and the differential drive gear.
2. The clearance should measure 0.05-0.28 mm (0.002-0.011 inch) with a maximum of 0.33 mm (0.013 inch).
3. If the clearance exceeds the maximum, check the contact surfaces of the first gear, differential drive gear and the synchronizer.
4. Replace any damaged or worn parts.
5. Measure the clearance between the second gear (2GR) and the third gear.
6. The clearance should measure 0.18-0.46 mm (0.007-0.018 inch) with a maximum of 0.51 mm (0.020 inch).
7. If the clearance exceeds the maximum, check the contact surfaces of the second gear, third gear, and the synchronizer.
8. Replace any damaged or worn parts.
9. Use a Rotunda 25-Ton Capacity General Purpose Press 014-00085 or equivalent and Bearing Pulling Attachment D84L-1123-A or equivalent to remove the bearing (fourth gear end) and the fourth gear.

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

10. Remove the snap ring from the output shaft.
11. Slide the synchronizer down to create enough of a gap to fit the adapter plate (Part of Rotunda 25-Ton Press Accessory Set 014-00131).
12. Use the adapter plate and hydraulic press to remove the third gear and second gear.
13. Remove the snap ring.
14. Use the hydraulic press and adapter plate to remove the synchronizer, synchronizer blocking ring, and the first gear.

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

15. Use the hydraulic press and adapter plate to remove the bearing (first gear end).

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

16. Clean and inspect the components for excessive wear.