Output Shaft: Service and Repair

DISASSEMBLE

RAD Four Speed Transmission Disassembled. (Typical):

1. Scribe alignment marks on synchronizer and blocker ring for alignment during installation, remove snap ring from front of shaft and slide third and fourth speed synchronizer assembly, blocker rings and third speed gear off shaft.
2. Remove next snap ring, then second speed gear thrust washer, second speed gear and blocker ring from shaft. The first and second speed synchronizer hub cannot be removed from output shaft.
3. Remove first gear thrust washer from rear of shaft, first gear spring pin retainer and slide first gear and blocker ring off shaft.

ASSEMBLY

Synchronizer Assembly. RAD Four Speed Transmission:

1. Place blocker ring on cone of first gear and slide assembly onto output shaft, engaging notches in blocker ring with inserts in synchronizer, and install first gear spring pin.
2. Place blocker ring on cone of second gear and slide assembly onto output shaft, engaging notches in blocker ring with inserts in synchronizer. Install second gear thrust washer and new snap ring.
3. Place blocker ring on cone of third gear and slide assembly onto output shaft, install third and fourth speed synchronizer, engaging notches on blocker ring with inserts on synchronizer. Install new snap ring.
4. Install first gear thrust washer and first gear spring pin retainer onto shaft. Oil grooves in thrust washer must be positioned against gear.