Input Shaft: Service and Repair

DISASSEMBLE

NOTE: Synchronizer rings are not interchangeable, keep in order of removal.

1. Press off 4th gear bearing cone using shaft protector tool No. D80L-625-4 and bearing pulling attachment tool No. D84L-1123-A or equivalents.
2. Remove 4th gear and synchronizer ring, then the retaining ring.
3. Press off clutch hub assembly, synchronizer ring and 3rd gear using shaft protector tool No. D80L-625-4 and pinion bearing cone removal tool No. T71P-4621-B or equivalents.
4. Press off 3rd gear bearing cone as described in step 1.
5. Remove synchronizer springs and keys from clutch hub.
6. Remove clutch hub from clutch hub sleeve.

ASSEMBLY
1. Slide clutch hub into clutch hub sleeve.
2. Install synchronizer keys and springs.
3. Press on new 3rd gear end bearing cone using shaft protector tool No. D80L-625-6, bearing cone replacement tool No. T88C-7025-DH and axle bearing plate tool No. T75L-1165-B or equivalents.
4. Align synchronizer ring groove and synchronizer key when installing synchronizer ring and clutch hub assembly.

Installing Clutch Hub Assembly:

5. Ensure ridge faces 3rd gear when installing clutch hub assembly.
6. Press on 3rd gear, synchronizer ring and clutch hub assembly, using shaft protector tool No. D80L-625-6, axle bearing/seal plate tool No. T75L-1165-B and bearing cone replacement tool No. T87C-77000-D or equivalents.
7. Install retaining ring, then press on synchronizer ring, 4th gear and bearing cone as described in step 6.