Assembly

1. Place output shaft in press with output shaft facing up.

2. Install 2nd gear bearing assembly onto output shaft. Lubricate assembly in transmission fluid.

3. Install 2nd gear onto output shaft. Install with synchronizer teeth facing up.

4. Install 2nd gear synchronizer internal ring, intermediate ring, then blocking ring onto gear. Intermediate ring is to be installed so that six driver cones are in respective recesses of gear.

5. Press 1-2 synchronizer body with ball like relief facing up, onto serrated portion of output shaft using tool Nos. J 36183 and J 36184 or equivalents. Body must be heated to 176° before being pressed onto output shaft. Three driving noses of 2nd gear synchronizer internal ring must match up with respective recesses of synchronizer body.

6. Install snap ring into groove in output shaft. Snap ring is available in three sizes, 0.112, 0.116, and 0.120 inches. Select thickest snap ring that will seat fully into snap ring groove.

7. Install synchronizer detent springs that are 0.700 inch long into pressure pieces, then insert into detent bores of synchronizer body.

8. Install 1-2 synchronizer sleeve onto synchronizer body. Detent springs must point to three recesses within teeth of synchronizer sleeve. Push sleeve flush against 2nd gear.

9. One at a time pull back pressure pieces far enough to place detent balls onto detent spring, then insert pressure pieces back into sleeve.

10. Place 1-2 synchronizer sleeve into neutral position, then install 1st gear synchronizer blocking ring into synchronizer body. The three stop cams of 1st gear synchronizer ring must point to respective recesses of synchronizer body.

11. Install 1st gear synchronizer intermediate ring into taper of synchronizer ring, then internal ring into taper of intermediate ring.

12. Install 1st gear bearing assembly onto output shaft, then lubricate with transmission fluid.

13. Install 1st gear onto 1-2 synchronizer assembly. Install so that six notches of intermediate ring are in respective recesses of gear.

14. Press thrust washer and reverse gear bearing race onto output shaft until fully seated, using tool No. J 36184. Heat washer and bearing race to 176°F before pressing onto output shaft.

15. Lubricate reverse gear bearing assembly with transmission fluid, then install onto output shaft.

16. Install reverse gear onto output shaft, then reverse synchronizer ring onto taper of reverse gear.

17. Press reverse synchronizer body onto serrated portion of output shaft using tool Nos. J 36183 and J 36184 or equivalents.






18. Install selective shim onto output shaft. Select thickest which will still allow snap ring to fully seat into output shaft groove. Refer to shim availability chart.

19. Install snap ring into groove of output shaft.

20. Install synchronizer detent springs that are 0.600 inches long into pressure pieces and insert pairs into detent bores of synchronizer body. Detent springs must point to three recesses of sleeve teeth. Position sleeve flush against synchronizer gear teeth of reverse gear.

21. Install reverse synchronizer sleeve with wider side of collar facing forward, onto gear teeth of synchronizer body.

22. One at a time pull back pressure pieces far enough to place detent balls onto detent spring, then insert keys back into sleeve.

23. Place reverse synchronizer sleeve into neutral position, then install snap ring into reverse synchronizer body.

24. Place output shaft in press with input end facing up, then install 3rd gear bearing assembly, and 3rd gear onto bearing seat of output shaft.

25. Install 3rd gear synchronizer ring onto taper of gear, then press 3-4 synchronizer body onto output shaft with flat surface toward 3rd gear using tool No. J 36184 or equivalent. Hub of synchronizer body must be heated to 176°F before being pressed onto output shaft.

26. Install selective snap ring into groove of output shaft. Snap ring is available in three sizes, 0.092,0.096, and 0.100 inches. Select thickest snap ring that will seat fully into snap ring groove.

27. Install synchronizer detent springs that are 0.600 inches into pressure pieces and insert pair into detent bores of synchronizer body. Detent springs must point to three recesses of teeth of 3-4 synchronizer sleeve.

28. Install 3-4 synchronizer sleeve onto synchronizer body. Push sleeve flush against synchronizer teeth of 3rd gear.

29. One at a time, pull back pressure pieces far enough to place detent balls onto detent springs, then insert pressure pieces back into sleeve.

30. Place 3-4 gear synchronizer sleeve into neutral position, then install 4th gear synchronizer ring into 3-4 synchronizer body. Three stop cams of 3-4 synchronizer ring must match up with respective recesses of synchronizer body.

31. Place output shaft assembly in support and assembly fixture, then install output shaft front bearing onto output shaft.

32. Install 4th gear input shaft onto output shaft front pocket bearing.