Output Shaft

Special Tools:

Disassembly
1. Remove the main shift rail, the first/second gear shifter fork, and the third/fourth gear shifter fork from the output shaft an assembly.

2. Remove the retaining ring.

3. CAUTION:
^ Hand-tighten the special tool to prevent gear damage.
^ Support the output shaft while using the press to prevent shaft damage.

Note: Install the special tool between the second gear and the third gear with the flat side of the special tool facing second gear.

Using the special tool and a press, remove the third/fourth synchronizer assembly, the third speed synchronizer blocking ring, and the third gear as an assembly.

4. Remove the bearing spacer and the needle bearing.

5. CAUTION: Hand-tighten the special tool to prevent gear damage.

Note: Install the special tool with the flat side facing reverse gear.

Using the special tool and a press, remove the fifth driven gear, the output shaft bearing assembly, and the first gear.
^ Discard the tapered roller bearing.

6. Remove the first gear bearing.

7. Remove the retaining ring.

8. Remove the thrust washer, the first gear synchronizer inner cone, the first gear synchronizer outer cone, and the first speed synchronizer blocking ring.

9. CAUTION: Do not press on the output shaft thrust flange or damage will occur.

Note: Install the special tool behind the second gear with the flat side of the special tool facing second gear.

Using the special tool and a press, remove the first/second synchronizer assembly and the second gear.
10. Remove the needle bearing.
11. Separate the first/second synchronizer assembly from the second gear.

12. Note: Tag all of the parts for correct assembly.

Remove the thrust washer, the second gear synchronizer outer and inner cones, and the second speed synchronizer blocking ring.

13. Using the special tool and a press, remove the input shaft pocket bearing.

Assembly
1. Soak the blocking rings in transmission fluid for ten minutes.
- Use MERCON(R) Multi-Purpose ATF Transmission Fluid XT-2-QDX or equivalent.

2. CAUTION: Do not support the output shaft by the thrust flange or damage will occur.

Using the special tool and a press, install the input shaft pocket bearing.

3. Lubricate the needle bearing with petroleum jelly and install the bearing.

4. Install the second gear.

5. Install the thrust washer.

6. Install the second gear synchronizer inner cone.
^ Align the second gear synchronizer inner cone and the thrust washer.

7. Install the second gear synchronizer outer cone.
^ Align the tabs on the cone with the pockets in the second gear.

8. Note: If not done so previously, soak the blocking ring in MERCON(R) Multi-Purpose ATF Transmission Fluid XT-2-QDX or equivalent for ten minutes.

Install the second speed synchronizer blocking ring.

9. Install the first/second synchronizer assembly so that the groove on the sleeve faces the front the output shaft.

10. CAUTION: The struts in the synchronizer must align with the pockets in the blocking ring.

Using the special tools and a press, install the first/second synchronizer assembly.

11. Note: If not done so previously, soak the blocking ring in MERCON(R) Multi-Purpose ATF Transmission Fluid XT-2-QDX or equivalent for ten minutes.

Install the first speed synchronizer blocking ring.
- Align the triangular marker on the blocking ring with the arrow on the synchronizer.

12. Install the first gear synchronizer outer cone with the tabs facing upward.

13. Install the first gear synchronizer inner cone.

14. Install the thrust washer.

15. Install the retaining ring with the bevel at the gap facing the synchronizer hub.

16. Lubricate the first gear bearing with petroleum jelly and install the bearing.

17. Install the first gear.
^ Align the pockets in the first gear with the tabs on the outer cone.

18. Using the special tool and a press, install a new output shaft bearing assembly.

19. Position the fifth driven gear with the chamfer facing the output shaft bearing assembly. Using the special tool and a press, install the fifth driven gear.

20. Install the needle bearing and the bearing spacer.

21. Install the third gear.

22. Note: If not done so previously, soak the blocking ring in MERCON(R) Multi-Purpose ATF Transmission Fluid XT-2-QDX or equivalent for ten minutes.

Install the third speed synchronizer blocking ring.

23. CAUTION: To prevent damage during installation, the struts in the synchronizer must index with the pockets in the third speed blocking ring.

Position the third/fourth synchronizer assembly with the groove facing upward. Using the special tool and a press, install the synchronizer assembly.

24. Install the retaining ring with the gap bevel facing the synchronizer.