Disassembly

GENERAL INFORMATION
Before disassembly of the input shaft, it is necessary to check the synchronizer stop ring gap. Use a feeler gauge to measure the gaps between the stop rings and the speed gears. The correct gaps are listed below:
- 1st - 1.04 - 1.72 mm (0.041 - 0.069 inch).
- 2nd - 0.94 - 1.72 mm (0.038 - 0.069 inch).
- 3rd - 1.37 - 1.93 mm (0.054 - 0.076 inch).
- 4th - 1.41 - 1.97 mm (0.056 - 0.078 inch).
- 5th - 1.37 - 1.93 mm (0.054 - 0.076 inch).

If a stop ring gap does not fall within the specifications, it must be inspected for wear and replaced. If the 1st or 2nd synchronizer stop ring is worn beyond specifications, the complete output shaft assembly must be replaced.

Input Shaft:

The input shaft incorporates the 3rd, 4th, and 5th speed gears and synchronizers on the assembly.

5th Synchro And Hub Snap Ring Removal:

PROCEDURE
1. Install bearing splitter behind 5th speed gear. Remove snap ring at 5th synchronizer hub on input shaft.

Remove Sychronizer Using Shop Press:

2. Remove synchronizer and gear using shop press.

Caged Needle Bearing Removal:

3. Remove caged needle bearing.

Split Thrust Washer Ring Removal:

4. Remove 4-5 gears split thrust washer ring.

Split Thrust Washer Removal:

5. Remove split thrust washer.

Split Thrust Washer Separation Pin:

6. Remove split thrust washer separation pin.

4th Gear Removal:

7. Remove 4th gear.

Caged Needle Bearing Removal:

8. Remove 4th gear caged needle bearing. Check the caged needle bearing for a broken retention spring.

3-4 Synchronizer Hub Snap Ring:

9. Remove blocking ring. Remove 3-4 synchronizer hub retaining snap ring.

3rd Gear Removal:

10. Install input shaft in shop press. Using bearing splitter, remove 3-4 synchronizer and 3rd gear.

3rd Gear Caged Needle Bearing:

11. Remove 3rd gear caged needle bearing. Check the caged needle bearing for a broken retention spring.
12. Inspect the input shaft for worn or damaged bearing races or chipped gear teeth. Replace as necessary.