Disassembly

DESCRIPTION
Output shaft includes 1st gear, 2nd gear, 5th gear and reverse gear (driven). Synchronizer assemblies are located between 1st and 2nd gears, and 5th and reverse gears. Output pinion gear is pressed onto inside of the tapered roller bearing. Gears on the output shaft run on needle bearings in a fiber collar, with the exception of the pinion gear, and 3rd gear and 4th gears (driven). The pinion gear, 3rd gear and 4th gear (driven) are an integral part of the output shaft. Tapered roller bearings are pressed onto both ends of output shaft. As with the input shaft, the clutch end bearing race is shimmed to provide preload for the output shaft.

Tapered Roller Bearing Removal:

PROCEDURE
1. Remove output shaft tapered roller bearing off of output shaft using Bearing Pulling Attachment D84L-11 23-A or equivalent.





2. Remove reverse gear, needle roller bearing and upper 5th/reverse gear synchronizer ring.





3. Remove snap ring. Remove 5th/reverse gear synchronizer assembly.





4. Remove lower 5th/reverse gear synchronizer ring, 5th gear and needle roller bearing.





5. Pull tapered roller bearing off output end of the output shaft using Bearing Pulling Attachment D84L-1123-A or equivalent.





6. Remove the snap ring.





7. Press pinion drive gear and 1st gear off together using Bearing Pulling Attachment D84L-1123-A or equivalent.





8. Remove needle bearing and 1st gear synchronizer ring.





9. Remove snap ring. Remove the 1st/2nd gear synchronizer assembly.





10. Remove synchronizer ring, 2nd gear and needle bearing from the output shaft.