Assembly
ASSEMBLY1. Secure mainshaft in a suitable soft jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2. Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upwards.
NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.
3. Position reverse gear synchronizer ring on taper of reverse gear.
4. Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320°F, ensuring not to heat for more than 15 minutes.
5. Position synchronizer body on mainshaft splines as to allow side with deeper hub faces down and short lugs on synchronizer ring engages gaps in synchronizer body.
6. Push or lightly tap synchronizer body down until it stops.
7. Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8. Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.
NOTE: Ensure snap ring is free of burrs before checking clearance.
9. Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.
Aligning Sleeve Synchronizer Body And Reverse Gear:
10. Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11. Align 3 cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth.
12. Insert three compression springs with pressure pieces in recesses of synchronizer body.
13. Push backpressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14. Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th reverse synchronizer body.
15. Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16. Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17. Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 320°F, ensuring not to heat for more than 15 minutes.
18. Place gear on mainshaft, until it seats against stop on mainshaft.
NOTE: If necessary to drive bearing on, do not drive against bearing cone.
19. On all except 4x4 and F-Super Duty models, check 5th gear endplay. Endplay should be 0.006-0.014 inch.
Installing Mainshaft Rear Tapered Roller Bearing:
20. On 4x4 and F-Super Duty models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21. On all models, invert mainshaft, then secure at input end, using suitable soft jawed vise.
22. Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23. Place 1st gear synchronizer ring on taper of 1st gear.
24. Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320F, ensuring not to heat for more than 15 minutes.
Installing Synchronizer Body:
25. Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26. Push or lightly tap synchronizer body down, until it stops against synchronizer ring.
NOTE: When properly installed, the word ENGINE will be visible on synchronizer body.
27. Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28. Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29. Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30. Position sliding sleeve over synchronizer body, with tapered collar facing downward (towards output end of mainshaft).
Aligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear:
31. Align 3 cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32. Insert 3 compression springs with pressure pieces in recesses of synchronizer body.
33. Push backpressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34. Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35. Push synchronizer ring downwards while pulling sliding sleeve into center position.
36. Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37. Heat thrust washer, using a suitable gear heater to approximately 320°F, ensuring not to heat for more than 15 minutes.
38. Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39. Heat 3rd gear bearing inner race to approximately 320°F, ensuring not to heat for more than 15 minutes.
40. Place race on mainshaft, then push down until fully seated against shaft stop.
41. Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42. After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43. Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44. Place 3rd gear synchronizer ring on taper of 3rd gear.
45. Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320°F, ensuring not to heat for more than 15 minutes.
46. Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47. Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48. Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49. Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50. Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51. Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52. Align 3 cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53. Push backpressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54. Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55. Push synchronizer ring downwards while pulling sliding sleeve into center position.
56. Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320°F, ensuring not to heat for more than 15 minutes.
57. Place bearing on mainshaft, until it seats against its stop on mainshaft.
58. An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.