Input Shaft: Service and Repair

Exploded View Of Input Shaft Gear:

1. Press off bearing cone from 4th gear end, using shaft protector D80L-625-4 and bearing pulling attachment D84L-1123-A or equivalents.
2. Remove 4th gear, needle bearing and sleeve.
3. Press off clutch hub assembly, synchronizer ring and 3rd gear, using shaft protector D80L-625-4 and puller plate D84L-1123-A or equivalents.
4. Remove needle bearing, then press off bearing cone from 3rd gear end, using shaft protector D80L-625-A and bearing pulling attachment D84L-1123-A or equivalents.
5. Remove Synchronizer rings and keys from clutch hub, then the clutch hub from the clutch hub sleeve.
6. Install clutch hub into clutch hub sleeve, then the synchronizer keys and springs. Lubricate needle bearing with transmission fluid, then install needle bearing.

Synchronizer Ring Groove And Synchronizer Key Alignment:

7. Press on 3rd gear, synchronizer ring and clutch hub assembly using shaft protector D80L-625-4, axle bearing seal plate T75L-1165-B and bearing cone replacer T88T-7025-B or equivalents. When installing synchronizer ring and clutch hub assembly, align synchronizer ring groove and synchronizer key.
8. Install ball and sleeve, then lubricate needle bearing and install.
9. Press on synchronizer ring, 4th gear and new bearing cone, using shaft protector D80L-625-4, axle bearing seal plate T75L-1165-B and bearing cone replacer T57L-1165-B or equivalents.
10. Press new bearing cone on 3rd gear end using shaft protector D80L-625-4, bearing cone replacer T88C-7025-DH and axle bearing seal plate T75L-1165-B or equivalents.