Output Shaft: Service and Repair

Output Shaft

Disassembly

1. Remove the bearing.
- Remove and discard the circlip.

- Using the special tools, remove and discard the bearing.

2. Remove 4th gear, remove and discard the snap-ring and remove the 3rd/4th gear synchronizer.

3. Remove the 3rd gear synchronizer ring and 3rd gear.

4. Remove the 2 half moon washers and 2nd gear.

5. Remove the inner and outer synchronizer rings and the synchronizer cone.

6. Remove and discard the snap-ring and remove the 1st/2nd gear synchronizer with reverse gear.

7. Remove the outer synchronizer ring.

8. Remove the synchronizer cone, inner synchronizer ring and the 1st gear.

9. Remove the bearing cone.
- Remove and discard the snap-ring.

- Using the special tools, remove and discard the bearing cone.

Assembly

1. Install the new bearing cone and new snap-ring.
1. Evenly heat the new bearing cone to approximately 176°F (80°C) and slide it onto the output shaft.

2. Install the new snap-ring.

2. Install the 1st gear, inner synchronizer ring and the synchronizer cone.

3. Install the outer synchronizer ring.

4. Install the new snap-ring.

5. Install the synchronizer cone and the outer and inner synchronizer rings.

6. Install the 2nd gear and the 2 half moon washers.

7. Install the 3rd gear and 3rd gear synchronizer ring.

8. Install the 3rd/4th gear synchronizer and new snap-ring.

9. Install 4th gear and using a suitable tube, install the new bearing and new circlip.