Output Shaft: Service and Repair

Special Tools:

DISASSEMBLY

1. Measure the output shaft clearances.
1 Measure the clearance between first gear and the differential drive gear.
2 Measure the clearance between second gear and secondary third gear.

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

2. Use an (A) arbor press, (B) Shaft Protector, and (C) Bearing Pulling Attachment 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.

NOTE: Inspect all the synchronizer components for wear and damage.

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

10. Use Dial Indicator/Magnetic Base to measure output shaft gear runout.
^ Inspect the output shaft for worn or damaged gears.
^ Inspect the output shaft for clogged oil passage.

11. Inspect the synchronizer blocking ring.
^ Measure the clearance from the side of the gear.
^ Inspect for smooth engagement with the gear.
^ Inspect for worn or damaged teeth or tapered surface.

NOTE: Set the synchronizer ring squarely in the gear, then measure around the circumference.

12. Inspect the synchronizer hub.
^ Inspect for worn or damaged splines, synchronizer insert groove or end surface.
^ Inspect for smooth hub sleeve movement when it is installed.

13. Measure the clearance between the first/second synchronizer hub and its shift fork.

ASSEMBLY

1. Use an arbor press, (A) Shaft Protector, (B) Bearing Cone Replacer and (C) Axle Bearing/Seal Plate to press on the bearing (first gear side).

NOTE: Whenever a bearing has been removed, it must be replaced with a new one.

2. Use an arbor press, (A) Shaft Protector, (B) Bearing Cone Replacer and (C) Axle Bearing/Seal Plate to press on the (D) first gear, (E) synchronizer blocking ring, and (F) reverse gear.

NOTE: When installing the synchronizer blocking ring, align the synchronizer blocking ring groove and synchronizer hub inserts.

3. Install the snap ring.

4. Use an arbor press, (A) Shaft Protector, (B) Bearing Cone Replacer, and (C) Axle Bearing/Seal Plate to press on the (D) synchronizer blocking ring, (E) second gear, and (F) third speed gear.

NOTE: When installing the synchronizer blocking ring, align the synchronizer blocking ring groove and synchronizer hub inserts.

5. Install the snap ring.

6. Use an (A) arbor press, (B) Shaft Protector, (C) Bearing Cone Replacer, and (D) Axle Bearing/Seal Plate to press on the (E) fourth speed gear.

7. Use an (A) arbor press, (B) Shaft Protector, (C) Bearing Cone Replacer, and (D) Axle Bearing/Seal Plate to press on the (E) bearing (fourth gear side).

8. Measure the output shaft clearances.
1 Measure the clearance between first gear and the differential drive gear.
2 Measure the clearance between second gear and third gear.

NOTE: If not within specifications, disassemble and reassemble the output shaft assembly.