Disassemble and Assemble

Special Tools:

DISASSEMBLY
1. Remove main gearshift rail and gearshift forks from output shaft.





2. Remove third-fourth synchronizer hub retaining ring from front of output shaft.





3. CAUTION: Only hand-tighten bearing puller to prevent damage to gear.

Install Bearing Pulling Attachment 205-DO02 (D79L-4621-A) or equivalent between second speed gear and third speed gear with flat side of puller toward third speed gear as shown.





4. CAUTION: Support output shaft while using press to prevent damage if dropped.

Using a press and Bearing Pulling Attachment 205-DO02 (D79L-4621-A) or equivalent, remove third/fourth synchronizer, third speed synchronizer blocking ring, and Third Gear (3GR) as an assembly.





5. Remove bearing assembly and third speed gear bearing spacer from output and fifth gear drive shaft.





6. CAUTION: Only hand-tighten puller to prevent damage to gear.

Install Bearing Pulling Attachment 205-DO02 (D79L-4621-A) or equivalent on forward side of first speed gear with flat side of puller toward gear as shown.





7. CAUTION: Support output shaft while using press to prevent damage if dropped.

Using a press and Bearing Pulling Attachment 205-DO02 (D79L-4621-A) or equivalent, remove fifth speed gear, tapered roller bearing and first speed gear. Discard tapered roller bearing.
8. Remove first gear needle bearing.





9. Remove retaining ring from rear of first-second synchronizer.





10. Remove the first-second synchronizer thrust washer, inner synchronizer cone, synchronizer middle blocker ring and outer blocker ring.





11. CAUTION: To prevent damage, do not press on output shaft thrust flange.

CAUTION: Support output shaft while using press to prevent damage if dropped.

Place Bearing Pulling Attachment 205-DO02 (D79L-4621-A) or equivalent behind Second Gear (2GR). Using press, remove first-second synchronizer assembly from hub.





12. NOTE: Identify parts for reassembly.

Remove first-second synchronizer assembly, second gear and needle bearing from output and fifth gear drive shaft.





13. Using Bearing Puller Attachment 205-DO02 (D79L-4621-A) or equivalent and press, remove input shaft pocket support bearing.

ASSEMBLY





1. CAUTION: Do not support output shaft by flange as damage will result.

Using press and Valve Stem Seal Replacer 303-383 (T91P-6571-A), install input shaft pocket support bearing onto output shaft.





2. Using petroleum jelly, lube and install second speed gear needle bearing.





3. Install second speed gear over needle bearing.





4. Install thrust washer over splines.





5. NOTE: Make sure inner splines of first and second gear synchronizer inner cone are indexed with thrust washer.

Install first and second gear synchronizer inner cone over thrust washer as shown.





6. NOTE: Soak blocker ring in MERCON Multi-Purpose (ATF) Transmission Fluid XT-2-QDX or equivalent for ten minutes prior to installation.

NOTE: Make sure tabs on blocker ring align with pockets on second gear.

Install second gear middle blocker ring over first and second gear synchronizer inner cone.





7. Install second gear outer blocker ring over middle blocker ring.





8. NOTE: Groove on synchronizer sleeve must face toward the front of output shaft.

Place first-second synchronizer onto output drive shaft.





9. NOTE: Make sure inserts on synchronizer align with pockets on outer blocker rings.

Using Bearing Replacer Tube 308-067 (M7L-7025-C), Remover/Replacer Tube 308-025 (T75L-7025-C) and Replacer/Adapter 308-239 (T96P-7025-A), press first-second synchronizer onto splines by tightening nut on Replacer/Adapter 308-239 (T96P-7025-A).





10. NOTE: Align triangular marker on outer blocker ring with arrow on synchronizer.

NOTE: Soak blocker ring in MERCON Multi-Purpose (ATF) Transmission Fluid XT-2-QDX or equivalent for ten minutes prior to installation.

Index and install first speed outer blocker ring.





11. NOTE: Tabs on middle blocker ring must face up.

NOTE: Soak blocker ring in MERCON Multi-Purpose (ATF) Transmission Fluid XT-2-QDX or equivalent for ten minutes prior to installation.

Install first speed middle blocker ring as shown.





12. Install first and second gear synchronizer inner cone as shown.





13. Install first and second speed synchronizer thrust washer as shown.





14. Install first speed retaining ring onto output shaft.





15. Using petroleum jelly, lube and install first speed needle bearing.





16. NOTE: Tabs on middle blocker must align with pockets on first gear.

Install First Gear (1GR) over needle bearing.





17. Place new tapered roller bearing onto output shaft. Using Remover/Replacer Tube 308-025 (T75L-7025-C) and Replacer/Adapter 308-239 (T96P-7025-A), press into place.





18. Press fifth speed gear onto output shaft with chamfer facing toward tapered bearing. Using Remover/Replacer Tube 308-025 (T75L-7025-C) and Replacer/Adapter 308-239 (T96P-7025-A), and threaded rod.





19. Install bearing and third speed gear bearing spacer assembly onto output shaft.





20. Install third speed gear over third speed gear bearing spacer.





21. NOTE: Soak blocker ring in MERCON Multi-Purpose (ATF) Transmission Fluid XT-2-QDX or equivalent for ten minutes prior to installation.

Install third speed synchronizer blocking ring over third gear.





22. CAUTION: Third/fourth synchronizer struts must index with pockets in third speed blocker ring assembly during press operation to prevent damage.

Using Bearing Replacer Tube 308-067 (T77L-7025-C) and press, support output shaft from rear, press third/fourth synchronizer onto output shaft as shown with groove forward.








23. Install third/fourth synchronizer retaining ring onto output and fifth gear drive shaft.