Output Shaft: Service and Repair

DISASSEMBLE

3rd/4th Synchronizer Removal:

1. Remove third-fourth synchronizer, third speed blocking ring, and third gear as an assembly, using universal press plate tool No. D79L-4621-A and suitable press.
2. Remove needle bearing assembly and spacer from output shaft.
3. Remove fifth gear snap ring, then fifth gear, using press plate.
4. Remove output shaft rear bearing and first gear.
5. Remove needle bearing assembly and sleeve.

NOTE: Sleeve is snugly fit onto output shaft.

6. Remove roll pin using a pencil magnet.
7. Remove first gear blocker ring assembly from output shaft, then second gear snap ring and thrust washer.
8. Remove second gear, second gear needle bearings, and spacer from output shaft.
9. Disengage spiral snap ring from slot in output shaft using a small screwdriver, then remove thrust washer.
10. Remove second gear blocker ring assembly, then first-second synchronizer from output shaft.

Anti-rattle Detent Spring And Ball Removal:

11. Carefully remove anti-rattle (detent) spring and ball from hub, spring and ball are under pressure.

CAUTION: Safety glasses must be worn during this procedure.

12. Do not attempt to remove 1st/2nd/reverse hub from output shaft. Hub and shaft are permanently assembled and machined as a set.
13. The sleeve, springs, and inserts may be removed from the hub after scratching or etching alignment marks on the hub and sleeve. If hub or sleeve is worn or damaged, the shaft and synchronizer must be replaced as an assembly.

ASSEMBLE
1. Install detent ball and spring in first-second synchronizer hub on output shaft.
2. Install first-second synchronizer assembly, and second gear blocker ring assembly onto output shaft.

NOTE: Align slots in blocker ring with tabs in first-second synchronizer.

3. Install thrust washer onto output shaft, then spiral snap ring.
4. Install second gear needle bearing, spacer, and second gear onto output shaft.

NOTE: Align slots in second gear with tabs on blocker ring assembly.

5. Install second gear thrust washer and snap ring.
6. Install first gear blocker ring assembly onto output shaft.

NOTE: Align slot in first gear blocking ring with tab on first-second synchronizer.

7. Install roll pin into output shaft.
8. While aligning notch in sleeve with roll pin, slide sleeve onto output shaft, then install needle bearing assembly over sleeve.
9. Install first gear onto output shaft.

NOTE: Align slots in first gear with tabs on first gear blocking ring assembly.

10. Install rear output shaft bearing onto output shaft.

NOTE: Bearing taper must face rear of the shaft.

11. Lubricate fifth gear splines with petroleum jelly, then install fifth gear on output shaft. Using a press and a capped piece of pipe, 1-1/4 X 14 inches, press fifth gear onto output shaft.

CAUTION: Ensure output shaft and gear splines are aligned. Damage can occur if not aligned properly prior to pressing gear onto output shaft.

12 Using snap ring pliers, install fifth gear snap ring, then install spacer and split needle bearing assembly onto output shaft
13. Using a press and a 1-1/2 inch deep well socket, install third-fourth synchronizer, third blocking ring, and third gear as an assembly.

NOTE: Ensure synchronizer hub faces the short end of the output shaft Hold the third gear against the synchronizer to maintain blocking ring alignment.