Output Shaft: Service and Repair

DISASSEMBLE

Tapered Roller Bearing Removal:

1. Remove tapered roller bearing from output shaft, using a suitable press and special tools as shown.
2. Remove reverse gear, needle roller bearing, and upper 5-R synchronizer ring, then disengage snap ring and remove 5-R synchronizer.

Exploded View Of Output Shaft:

3. Remove lower 5-R synchronizer ring, fifth gear, and needle roller bearing, then remove tapered roller bearing from output end of output shaft using tools as shown.
4. Disengage snap ring, then remove pinion gear and first gear together using bearing puller tool No. D84L-1123-A, or equivalent, and a suitable press.
5. Remove needle roller bearing and first gear synchronizer ring, then disengage snap ring and remove 1-2 synchronizer.
6. Remove synchronizer ring, second gear, and needle bearing from output shaft.

ASSEMBLE
1. Install needle bearing, second gear and second synchronizer ring on output shaft.

1-2 Synchronizer Orientation:

2. Install 1-2 synchronizer with small collar facing outward, then position first gear synchronizer ring, needle bearing and first gear on shaft.
3. Using a suitable driver and press, carefully install pinion gear on output shaft splines and install a new snap ring.

NOTE: Pinion gear can only be installed in one direction.

4. Using a suitable driver and press, install tapered roller bearing on output shaft end, then install needle bearing, fifth gear, and reverse synchronizer ring.

Synchronizer Components:

5-R Synchronizer Orientation:

5. Assemble synchronizer hub components and ring, then install 5-R synchronizer assembly with small collar facing outward. Install a new snap ring.
6. Install upper 5-R synchronizer ring, needle bearing and reverse gear on output shaft, then use a suitable driver and press to install tapered roller bearing.