Disassembly And Assembly
DISASSEMBLY
PART IDENTIFICATION
| Callout | Part |
| 1. | Front Bearing |
| 2. | Fifth Gear |
| 3. | Sixth Gear |
| 4. | Third Gear |
| 5. | 3-4 Synchronizer |
| 6. | 5-6 Synchronizer |
- Using a suitable tool, remove snap ring from the rear side of the shaft holding the 3-4 synchronizer hub.
- Using the (special tool #9647, Puller) (2) and a press, place the puller under the 3rd gear (1) and press the shaft to remove the 3-4 synchronizer assembly.
- Remove the 3rd gear needle bearing (1) from the shaft assembly.
- Remove the needle bearing spacer (1) from the shaft assembly.
- With a suitable tool, remove the snap ring (2) holding the 3rd gear thrust washer (1).
- Remove the 3rd gear thrust washer (1).
- Remove the indexing pin (1) from the shaft and remove 6th gear.
- Remove the 6th gear needle bearing (1) and synchronizer ring (2) from the assembly.
- Remove the needle bearing spacer (1). Using a suitable tool, remove the snap ring (2) retaining the 5-6 synchronizer assembly.
- With suitable tool supporting 5th gear and a press, press the shaft to remove the 5-6 synchronizer assembly (1) and the 5th gear.
- Remove the 5th gear needle bearing (1).
- With a suitable tool, remove the snap ring (1) retaining the front bearing.
- Using a suitable tool and a press, support the inner race of the bearing (1) and press the shaft to remove the bearing.
ASSEMBLY
- Using a press, press the inner race of the input bearing (snap ring groove towards the rear) on the shaft using (special tool #W-262, Installer, Bearing).
- Due to manufacturing tolerances, install a NEW
, LARGEST
selective snap-ring (1) that fits into the groove. Be sure to tap the ends of the snap-ring to fully set the ring.
- Install the 5th gear needle bearing (1) to shaft. Apply specified oil to bearing.
- Install 5th gear and 5th gear synchronizer ring, be sure ring tabs are indexed to the gear and hub to prevent damage. Using the (special tool #D-389, Installer, Bearing) (2) and a press, support the 5-6 synchronizer hub (dot on hub towards rear of shaft, deep step on sleeve towards front), and press the shaft until the hub is fully seated.
- Due to manufacturing tolerances, install a NEW
, LARGEST
selective snap-ring (1) that fits into the groove. Install the needle bearing thrust washer (2).
- Install the 6th Gear needle bearing (1) and synchronizer ring to the assembly. Apply specified oil to the needle bearing. Be certain that the synchronizer ring fingers (2) are indexed properly to the hub.
- Install the 6th gear (1) to assembly.
- Install the 3rd gear thrust washer indexing pin (1) into the hole in the shaft.
- Find the indexing notch in the 3rd gear thrust washer (1).
- Align the 3rd gear thrust washer (1) with the pin and retain in place with a NEW
, LARGEST
selective snap ring (2) that fits in the groove. Be sure to tap the ends of the snap-ring to fully set the ring.
- Install the 3rd gear needle bearing spacer (1) to the assembly. Apply specified oil to the needle bearing.
- Install the 3rd gear needle bearing (1) to the assembly.
- Install the 3rd gear assembly and synchronizer rings. Be certain that the synchronizer ring fingers are indexed properly to the gear.
- Align the synchronizer fingers with the hub, place the 3-4 synchronizer (deep part of hub towards the back of shaft, with the stepped edge of sleeve towards the rear) on the assembly. Support the aligned parts with (special tool #6448A, Installer, Bearing/Gear) on a press and press the shaft to install the hub and synchronizer on the shaft assembly.
- Due to manufacturing tolerances, install a NEW , LARGEST selective snap-ring (1) that fits in the groove. Be sure to tap the ends of the snap-ring to fully set the ring.