Output Shaft: Service and Repair

DISASSEMBLY

NOTE: Label parts for assembly.

Mainshaft Assembly:

1. Remove bearing from fourth gear end of mainshaft.
2. Remove fourth gear and synchronizer blocker ring.
3. Remove 3-4 synchronizer retaining ring, then the third and fourth gear synchronizer assembly, blocker ring and third gear from main shaft.
4. Remove second and third thrust washer retaining ring, then the two-piece second-third gear thrust washer.
5. Remove second gear and blocker ring, then the 1-2 synchronizer retaining ring.
6. Remove 1-2 synchronizer assembly, blocking ring and first gear from main shaft.
7. If damaged, remove tapered roller bearing from pinion end of main shaft using pinion bearing cone remover tool No. D79L-4621-A, or equivalent, and an arbor press.

ASSEMBLY
1. Reverse procedure to assemble, noting the following:
a. Oil all parts and gear bores with transaxle fluid.

Gear And Synchronizer Hub Alignment:

b. When assembling synchronizers, index marks must be aligned.

Synchronizer Sleeve Installation:

c. Tab on synchronizer spring is installed into groove of insert, then snapped into place. Tab of second spring is installed into same insert on opposite side of synchronizer assembly, then rotated in opposite direction and snapped into place.

Synchronizer Assembly:

d. When assembling synchronizers and sleeves, hubs must be held squarely to prevent jamming.