Secondary Shaft Disassembly/Assembly

Disassembly





1. Remove the (A) transmission primary shaft pilot bearing, (B) the bearing outer snap ring, (C) the third and fourth synchronizer spacer and (D) the thrust bearing.





2. Remove the (A) third/fourth synchronizer, (B) the third gear synchronizer blocking ring, (C) the third gear and (D) the gear bearing.





3. Use an (A) arbor press to remove the (B) output shaft center bearing, the (C) first gear, the (D) first/ second synchronizer, the (E) first/second synchronizer blocking rings, and the (F) second gear.

Caution:
- Make sure that the secondary shaft flange does not contact or ride up onto the press cradle. Improper positioning can result in component damage.

Assembly





1. Use (A) Dial Indicator with Bracketry to check the (B) output shaft runout.
1) Check runout in several places along the secondary shaft. If runout exceeds specification, replace the shaft.





2. Identify the synchronizer blocking ring.
1) Brass third gear synchronizer blocking ring.
2) Brass first and fourth gear synchronizer blocking ring.
3) Carbon second gear synchronizer blocking ring.





3. Inspect the (A) synchronizer blocking rings for proper contact with the (B) cone surface of the gears.





4. Inspect the (A) synchronizer blocking rings for wear on the (B) gear.
1) If clearance is less than specification, replace the ring or gear.





5. Assemble the first and second gear assembly.
1) Install the second gear needle bearing.
2) Install the second gear.
3) Install the second synchronizer blocking ring.
4) Install the first/second synchronizer with the identification hole in the sleeve facing second gear.
5) Install the first gear synchronizer blocking ring.
6) Install the first gear.
7) Install the first gear needle bearing.
8) Install the primary bearing spacer.
9) Position the secondary shaft center bearing.





6. Press the secondary shaft center bearing into position using Bearing Driver Attachment SST 49 UN17 101, Mainshaft Locknut Wrench SST 49 1243 465A, Axle Bearing/Seal Plate SST 49 H027 002 and Bearing Cone Replacer SST 205-004 (T53T-4621-B) or equivalent.





7. Install the (D) third gear bearing, the (C) third gear, the (B) third gear synchronizer blocking ring, and the (A) third/fourth synchronizer.

Note:
- Install the third/fourth synchronizer with the chamfer on the sleeve facing fourth gear.





8. Install the (D) thrust bearing, the (C) third and fourth synchronizer spacer, the (B) bearing outer snap ring, and the (A) transmission primary shaft pilot bearing.








9. Check the third/fourth clutch hub end play.
1) If clearance is not within specification, select the proper bearing outer snap ring.