Disassembly

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





1. Inspect the output shaft assembly for:
(A) Clearance between first gear and the differential drive gear.
(B) Clearance between second gear and third gear.





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. Use an (A) arbor press, (B) shaft protector, and (C) Bearing Pulling Attachment to press off the (D) fourth speed gear.





4. Remove the snap ring.





5. Use an (A) arbor press, (B) shaft protector, and (C) Bearing Pulling Attachment to press off the (D) third speed gear and (E) second gear.





6. Remove the synchronizer blocking ring.

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





7. Remove the snap ring.





8. Use an (A) arbor press, (B) shaft protector, and (C) press blocks to press off the (D) synchronizer hub, (E) synchronizer blocking ring, and (F) first gear.

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





9. Use a (A) shaft protector and (B) Bearing Pulling Attachment to press off the (C) bearing (first gear end).





10. Disassemble the synchronizer assembly.

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

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





11. Use Dial Indicator with bracketry TOOL-4201 to check output shaft gear runout. Inspect the output shaft for:
- Worn or damaged gears.
- Clogged oil passage.





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





14. Inspect the clearance between the first/second synchronizer hub and its shift fork.