Input Shaft

DISASSEMBLY 

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1. Using a suitable tool, remove snap ring from the rear side of the shaft holding the 3-4 synchronizer hub.

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   1 - 3/4 Synchronizer Hub Snap Ring

2. Using the special tool # 9647, (Puller) and a press, place the puller under the 3rd gear and press the shaft to remove the 3-4 synchronizer assembly.

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   1 - 3rd Gear

   2 - Puller 9647

3. Remove the 3rd gear needle bearing from the shaft assembly.

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   1 - 3rd Gear Needle Bearing

4. Remove the needle bearing spacer from the shaft assembly.

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   1 - Needle Bearing Spacer

5. With a suitable tool, remove the snap ring holding the 3rd gear thrust washer.

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   1 - 3rd Gear Thrust Washer

   2 - Snap Ring

6. Remove the 3rd gear thrust washer.

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   1 - 3rd Gear Thrust Washer

7. Remove the indexing pin from the shaft and remove 6th gear.

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   1 - Indexing Pin

   2 - 6th Gear

8. Remove the 6th gear needle bearing and synchronizer ring from the assembly.

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   1 - 6th Gear Needle Bearing

   2 - Synchronizer Ring

9. Remove the needle bearing spacer. Using a suitable tool, remove the snap ring retaining the 5-6 synchronizer assembly.

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   1 - Needle Bearing Spacer

   2 - 5/6 Synchronizer Snap Ring

10. With suitable tool supporting 5th gear and a press, press the shaft to remove the 5-6 synchronizer assembly and the 5th gear.

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    1 - 5/6 Synchronizer Assembly

11. Remove the 5th gear needle bearing.

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    1 - 5th Gear Needle Bearing

12. With a suitable tool, remove the snap ring retaining the front bearing.

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    1 - Snap Ring

13. Using a suitable tool and a press, support the inner race of the front bearing and press the shaft to remove the bearing.

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    1 - Front Bearing

ASSEMBLY 

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1. Using a press, press the inner race of the input bearing (snap ring groove towards the rear) on the shaft using special tool # W-262, (Bearing Installer).
2. Due to manufacturing tolerances, install a NEW  , LARGEST  selective front bearing snap-ring that fits into the groove. Be sure to tap the ends of the snap-ring to fully set the ring.

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   1 - Front Bearing Snap Ring (Selective)

3. Install the 5th gear needle bearing to shaft. Apply specified oil to bearing.

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   1 - 5th Gear Needle Bearing

4. Install 5th gear and 5th gear synchronizer ring, be sure ring tabs are indexed to the gear and hub to prevent damage. Using the special tool # D-389, (Bearing Installer) and a press, support the 5-6 synchronizer hub (dot on hub towards rear of shaft, deep step on sleeve towards front), and press the shaft until the hub is fully seated.

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   1 - 5/6 Synchronizer Hub

   2 - Installer, Bearing D-389

5. Due to manufacturing tolerances, install a NEW  , LARGEST  selective snap-ring that fits into the groove. Install the needle bearing thrust washer.

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   1 - 5/6 Synchronizer Snap Ring (Selective)

   2 - needle bearing thrust washer

6. Install the 6th Gear needle bearing and synchronizer ring to the assembly. Apply specified oil to the needle bearing. Be certain that the synchronizer ring fingers are indexed properly to the hub.

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   1 - 6th Gear Needle Bearing

   2 - Synchronizer Ring

7. Install the 6th gear to assembly.

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   1 - 6th Gear

8. Install the 3rd gear thrust washer indexing pin into the hole in the shaft.

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   1 - 3rd Gear Thrust Washer Indexing Pin Hole

9. Find the indexing notch in the 3rd gear thrust washer.

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   1 - 3rd Gear Thrust Washer Indexing Notch

10. Align the 3rd gear thrust washer with the pin and retain in place with a NEW  , LARGEST  selective snap ring that fits in the groove. Be sure to tap the ends of the snap-ring to fully set the ring.

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    1 - 3rd Gear Thrust Washer

    2 - Snap Ring (Selective)

11. Install the 3rd gear needle bearing spacer to the assembly. Apply specified oil to the needle bearing.

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    1 - 3rd Gear Needle Bearing Spacer

12. Install the 3rd gear needle bearing to the assembly.

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    1 - 3rd Gear Needle Bearing

13. Install the 3rd gear assembly and synchronizer rings. Be certain that the synchronizer ring fingers are indexed properly to the gear.

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    1 - 3rd Gear

    2 - 3rd Gear Synchronizer Rings

14. Align the synchronizer fingers with the hub, place the 3-4 synchronizer (deep part of hub towards the back of shaft, with the stepped edge of sleeve towards the rear) on the assembly. Support the aligned parts with special tool # 6448A, (Bearing/Gear Installer) on a press and press the shaft to install the hub and synchronizer on the shaft assembly.

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    1 - 3/4 Synchronizer

    2 - Installer, Bearing/Gear 6448A

15. Due to manufacturing tolerances, install a NEW  , LARGEST  selective 3-4 synchronizer hub snap-ring that fits in the groove. Be sure to tap the ends of the snap-ring to fully set the ring.

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    1 - 3/4 Synchronizer Hub Snap Ring (Selective)