Disassemble and Assemble

Special Tool:

DISASSEMBLY





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





2. Remove bearing as an assembly and third speed gear bearing spacer from output and fifth gear drive shaft.





3. Remove fifth speed gear snap ring.





4. Using a press and Bearing Pulling Attachment D79L-4621-A or equivalent, remove fifth speed gear.





5. Remove output shaft rear bearings.





6. Remove First Gear (1GR).





7. NOTE: There is a snug fit between the input bearing spacer and the output and fifth gear drive shaft.

Remove output and fifth gear drive shaft as an assembly and input bearing spacer.





8. Remove first and second speed synchronizer hub pin using a pencil magnet.





9. Remove first and second gear synchronizer inner cone, first and second gear synchronizer outer cone and synchronizer blocking ring as an assembly from output and fifth gear drive shaft.





10. Remove second gear snap ring and thrust washer.





11. Remove Second Gear (2GR) from output and fifth gear drive shaft.





12. Remove bearing assembly and second speed gear bearing spacer.





13. Disengage output shaft bearing to case snap ring from slot in output and fifth gear drive shaft using a small screwdriver.





14. Remove output shaft bearing to case snap ring and first and second speed synchronizer thrust washer from output and fifth gear drive shaft.
15. Remove first and second gear synchronizer inner cone, first and second gear synchronizer outer cone and synchronizer blocking ring as an assembly.





16. Remove first/second synchronizer from output and fifth gear drive shaft.





17. NOTE: The first/second speed synchronizer and hub is serviced only as an assembly with the output and fifth gear drive shaft. No attempt should be made to separate the hub from the output and fifth gear drive shaft.

The synchronizer blocking spring and synchronizer hub inserts may be removed from the hub after scratching or etching alignment marks on the hub and synchronizer. The only parts that can be serviced are the synchronizer blocking springs and synchronizer hub inserts. If the hub or sleeve is worn or damaged, the output and fifth gear drive shaft and synchronizer must be replaced as an assembly.

ASSEMBLY





1. Install synchronizer hub inserts in first/second synchronizer hub on output and fifth gear drive shaft.





2. NOTE: Align slots in synchronizer blocking ring with tabs in first/second synchronizer.

Install first/second synchronizer as an assembly, first and second gear synchronizer inner cone, first and second gear synchronizer outer cone and synchronizer blocking ring as an assembly onto output and fifth gear drive shaft.





3. Install first and second speed synchronizer thrust washer onto output and fifth gear drive shaft. Install output shaft bearing to case snap ring using Spiral Snap Ring Replacer T85P-7025-A.





4. Install bearing and second speed gear bearing spacer.





5. NOTE: Align slots in second gear with tabs on synchronizer blocking ring assembly.

Install second gear onto output and fifth gear drive shaft.





6. Install thrust washer. Install second gear snap ring using snap ring pliers.





7. NOTE: Align slot in first gear synchronizer blocking ring with tab on first/second synchronizer.

Install first and second gear synchronizer inner cone, first and second gear synchronizer outer cone and synchronizer blocking ring as an assembly onto output and fifth gear drive shaft.





8. NOTE: Use pencil magnet if necessary.

Drop first and second speed synchronizer hub pin into output and fifth gear drive shaft.





9. While aligning notch in input bearing spacer with first and second speed synchronizer hub pin, slide input bearing spacer onto output and fifth gear drive shaft.

Install needle bearing assembly over input bearing spacer.





10. NOTE: Align slots in first gear with tabs on first gear synchronizer blocking ring as an assembly.

Install first gear onto output and fifth gear drive shaft.





11. CAUTION: Make sure the output and fifth gear drive shaft and first gear splines are carefully aligned. If splines are improperly aligned, damage could occur when the first gear is pressed onto the output and fifth gear drive shaft.

Install rear output shaft bearing onto output and fifth gear drive shaft. The bearing taper must face the rear of the output and fifth gear drive shaft.





12. Lubricate fifth speed gear splines with petroleum jelly and position on output and fifth gear drive shaft. Using a press and a capped length of pipe, 31.75 mm inner diameter x 356 mm (1-1/4 inch inner diameter x 14 inch), press fifth speed gear onto output and fifth gear drive shaft.





13. Using snap ring pliers, install fifth speed gear snap ring.





14. Install third speed gear bearing spacer and bearing as an assembly onto output and fifth gear drive shaft.





15. NOTE: Before pressing components together, make sure the synchronizer hub faces the short end of the output and fifth gear drive shaft. Hold third gear against the synchronizer to maintain synchronizer blocking ring alignment.

Using a press and a 1-1/2 inch-deep well socket, install third/fourth synchronizer, synchronizer blocking ring and third gear as an assembly.