Disassembly

CAUTION: When pressing off components hold the shaft so that it does not fall.





1. Inspect the input shaft assembly for:
(A) Clearance between the third and second gears.
(B) Clearance between fourth gear and the bearing cone.





2. Use an (A) arbor press, (B) shaft protector, and (C) Bearing Pulling Attachment D84L-1123-A to press off the (D) bearing (fourth gear end).
3. Remove fourth gear and the synchronizer blocking ring.

CAUTION: The synchronizer blocking rings are not interchangeable. Be sure to keep them in the order that they were removed.





4. Remove the snap ring.





5. Use an (A) arbor press, (B) shaft protector, and (C) Pinion Bearing Cone Remover T71P-4621-B to press off the (D) synchronizer hub assembly, (E) synchronizer blocking ring, and (F) third gear.

CAUTION: The synchronizer blocking rings are not interchangeable. Be sure to keep them in the order that they were removed.





6. Use an arbor press, (A) shaft protector, and (B) Bearing Pulling Attachment D84L-1123-A to press off the (C) bearing (third gear end).





7. Disassemble the synchronizer assembly.

NOTE: Prior to disassembly, note the position of the index marks.

(1) Remove the two synchronizer blocking springs.
(2) Remove the three synchronizer hub inserts.
(3) Separate the synchronizer hub from the reverse gear.





8. Use Dial Indicator With Bracketry TOOL-4201-C to check input gear runout. Inspect the input shaft for worn or damaged gears.





9. Inspect the synchronizer blocking rings for:
- Clearance from the side of the gear.
- Smooth engagement with the gear.
- Worn or damaged teeth or tapper surface.
10. Inspect the synchronizer hub for:
- Worn or damaged splices, synchronizer insert groove or end surface.
- Smooth hub sleeve movement when it is installed.





11. Inspect the clearance between the third/fourth synchronizer hub and its shift fork.