Output Shaft, 5th, 6th, and Reverse - Assembly

ASSEMBLY





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





2. Install reverse gear (2) and the synchronizer (1) onto the output shaft together.





3. Install the reverse synchronizer snap ring (1) using Snap Ring Pliers (2).





4. Install the reverse synchronizer lock ring assembly (1, 2) onto the output shaft.





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






NOTE: Insure synchronizer in the neutral position.

6. Install fifth gear (2) and the fifth/sixth gear synchronizer (1) onto the output shaft together.





7. Using Snap Ring Pliers (1) install the snap ring (2) holding the fifth/sixth gear synchronizer (3).





8. Install sixth gear needle bearing (1) onto the output shaft.





9. Install sixth gear (1) 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.





10. Using a press (1) and installer L-4507 (2) install the case side new roller bearing (3) onto the output shaft (4).






NOTE: The retaining bolt has left hand threads.

11. Install the new retaining bolt (2) for the case side tapered roller bearing (3) and tighten to 100 Nm (74 ft. lbs.).





12. Using Installer 6052 (1) install the new bellhousing side roller bearing (2) onto the output shaft.