MAINSHAFT W/Input Shaft: Disassembly

Disassemble the geartrain housing. See GEARTRAIN HOUSING .
Mount the main shaft in a vise with protective jaws.
Remove first gear idler gear (2) using a jaw puller (1).

Fig 1: Removing First Gear Idler Gear
Courtesy of DAIMLERCHRYSLER CORP.
Remove the reverse gear synchronizer assembly (1).

Fig 2: Removing Reverse Gear Synchronizer Assembly
Courtesy of DAIMLERCHRYSLER CORP.
Remove the synchronizer ring (1) and idler gear (2) for reverse gear.

Fig 3: Removing Synchronizer Ring & Idler Gear For Reverse Gear
Courtesy of DAIMLERCHRYSLER CORP.
Remove first gear needle bearing (1) and sleeve (2).

Fig 4: Removing First Gear Needle Bearing & Sleeve
Courtesy of DAIMLERCHRYSLER CORP.
Remove the thrust washer (1), first gear idler gear (2), and first gear idler needle bearing (3).

Fig 5: Removing Thrust Washer, First Gear Idler Gear & First Gear Idler Needle Bearing
Courtesy of DAIMLERCHRYSLER CORP.
Remove the friction ring (1), cone ring (2), and the synchronizer ring (3).

Fig 6: Removing Friction Ring, Cone Ring & Synchronizer Ring
Courtesy of DAIMLERCHRYSLER CORP.
Remove the locking ring (1) using pliers. Remove the 1st/ 2nd gear synchronizer using the jaw puller.

Fig 7: Removing Locking Ring & 1st/2nd Gear Synchronizer
Courtesy of DAIMLERCHRYSLER CORP.
Remove the synchronizer ring (1), cone ring (2), and friction ring (3).

Fig 8: Removing Synchronizer Ring, Cone Ring & Friction Ring
Courtesy of DAIMLERCHRYSLER CORP.
Remove the second gear idler gear (1) and needle bearing (2).

Fig 9: Removing Second Gear Idler Gear & Needle Bearing
Courtesy of DAIMLERCHRYSLER CORP.
Remove the main shaft (1) from the input shaft (2).
Remove the synchronizer ring (5) and the clutch body (4).
Remove the cylindrical roller bearing (3) from the input shaft (2).

Fig 10: Removing Main Shaft, Synchronizer Ring, Clutch Body, Cylindrical Roller Bearing & Input Shaft
Courtesy of DAIMLERCHRYSLER CORP.
Remove the input shaft (2) from the vise.
Clamp the main shaft (3) in the vise with input end up.

Fig 11: Clamping Main Shaft & Removing Locking Ring
Courtesy of DAIMLERCHRYSLER CORP.
Remove the locking ring (1), pull off the synchronizer cone (2) and the clutch body using the jaw puller.
Remove the synchronizer ring (1) and the clutch body (2).

Fig 12: Removing Synchronizer Ring & Clutch Body
Courtesy of DAIMLERCHRYSLER CORP.
Remove the 6th gear idler gear (1) and needle bearing (2).

Fig 13: Removing 6th Gear Idler Gear & Needle Bearing
Courtesy of DAIMLERCHRYSLER CORP.
Remove the main shaft (3) from the vise.