Disassembly

NOTE: Refer to image for parts identification during disassembly and assembly of the output shaft.





1. Remove input shaft and output shaft pilot bearing from output shaft, if necessary.





2. Measure and note thrust clearance of output shaft gears. First gear clearance should be 0.10 - 0.40 mm (0.004 - 0.0197 inch). Second and third gear clearance should be 0.10 - 0.30 mm (0.003 -0.0118 inch).





3. Remove output shaft fifth gear snap ring with two screwdrivers.





4. Using Bearing Splitter P-334, or equivalent or suitable press plates positioned under first gear, press fifth gear, rear bearing, first gear, and first gear thrust washer off output shaft.
5. Remove first gear thrust washer locating pin from output shaft.
6. Remove first gear needle roller bearing from output shaft.
7. Remove first gear spacer from output shaft.
8. Remove first gear synchronizer ring.
9. Remove select fit snap-ring holding the 1-2 synchronizer/reverse gear onto the output shaft.





10. Using Bearing Splitter P-334, or equivalent or suitable press plates positioned under second gear, press 1-2 synchronizer/reverse gear and second gear from output shaft.
11. Remove second gear needle roller bearing from the output shaft or second gear.





12. Remove select fit snap-ring holding the 3-4 synchronizer onto the output shaft.





13. Using Bearing Splitter P-334, or equivalent or suitable press plates positioned under third gear, press the 3-4 synchronizer and third gear from output shaft.
14. Remove third gear needle roller bearing from output shaft or gear.