Output Shaft, 1st to 4th - Assembly

ASSEMBLY





1. Install the first gear needle bearing (2) onto the output shaft (1).





2. Install the first gear (1) onto the output shaft (2).





3. Install the first gear blocker ring (1) onto the output shaft (2).





4. Install the first/second gear synchronizer (1) onto the output shaft (2).





5. Install the first/second gear synchronizer snap ring (1) onto the output shaft using a pair of Snap ring Pliers (2)
.




6. Install the second gear blocker ring (2) on the output shaft (1).





7. Install the second gear needle bearing (1) onto the output shaft (2).





8. Install second gear (1) onto the output shaft (2).





9. Install the second gear locking ring assembly (1, 2) onto the output shaft (3).





10. Install the third gear needle bearing (1) onto the output shaft (2).





11. Install third gear (2) and synchronizer (1) onto the output shaft (3).





12. Install the snap ring (1) at the 3rd/4th gear synchronizer (3).





13. Install the forth gear needle bearing (1) onto the output shaft.





14. Install the forth gear (1) and blocker (2) onto the output 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:

- 0.4 mm (0.016 in)

If a stop ring gap does not fall within the specifications it must be inspected for wear and replaced.





15. Using a Press and Installer L-4507 (1) to install the new case side output shaft bearing (2) onto the output shaft.






NOTE: The retaining bolt has left hand threads.

16. Install the new retaining bolt (2) onto the case side output shaft (3) and tighten to 100 Nm (74 ft. lbs.).





17. Using a Press and Installer 6052 (1) to install the new bellhousing side output shaft bearing (2).