Output Shaft: Description: Assembly

WARNING: This page is about a different variant/trim than selected.

Fig 1: Cross Sectional View - Output Shaft

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1 - FIFTH GEAR

2 - FOURTH GEAR

3 - THIRD GEAR

4 - SECOND GEAR

5 - 1/2 SYNCHRONIZER

6 - FIRST GEAR

7 - ROLLER BEARING (2)

8 - NEEDLE BEARING

9 - BUSHING

Fig 2: First Gear Roller Bearing

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1 - ROLLER BEARING

2 - SMALLER RING UP

Install first gear roller bearing (1) to shaft with smaller diameter cage ring (2) facing outward. See See Fig 2.Fig 1.

Fig 3: First Gear
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1 - FIRST GEAR
Install first gear (1). See Fig 3.

Fig 4: First Gear Roller Bearing
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1 - LARGER RING UP

2 - ROLLER BEARING
Install other first gear roller bearing (2) with larger diameter cage ring (1) facing outward. See Fig 4.

Fig 5: First Gear Friction Cone
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1 - FRICTION CONE
Install first gear friction cone (1).

Fig 6: First Gear Friction Ring
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1 - FRICTION RING
Install first gear friction ring (1). See Fig 6. Align teeth of friction ring with notches in gear.

Fig 7: First Gear Blocker Ring
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1 - BLOCKER RING

Install first gear blocker ring (1). See Fig 7.

Fig 8: Install First Gear Synchronizer Hub

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1 - INSTALLER 6448A

2 - SYNCHRONIZER HUB

3 - BLOCKER RING

Install 1/2 synchronizer hub with Installer 6448A (3). See Fig 8.

Fig 9: Synchronizer Hub/Ring Alignment
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1 - SYNCHRONIZER HUB

2 - BLOCKER RING

Line up blocker ring (2) with the synchronizer hub (1). See Fig 9.

Fig 10: Synchronizer Sleeve Orientation
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1 - SYNCHRONIZER SLEEVE

2 - GROOVE TOWARDS FIRST GEAR
Install 1/2 synchronizer sleeve (1) with groove towards first gear (2). See Fig 10.

Fig 11: Synchronizer Strut
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1 - SYNCHRONIZER STRUT
Install three synchronizer strut (1) assemblies. See Fig 11.

Fig 12: Install Second Gear Bearing Bushing
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1 - INSTALLER 6448A

2 - BUSHING
Using Installer 6448A (1), install second gear bearing bushing (2) until it bottoms on synchronizer hub. See Fig 12.

Fig 13: Second Gear Needle Bearing
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1 - NEEDLE BEARING
Install second gear needle bearing (1). See Fig 13.

Fig 14: Second Gear Synchronizer Ring
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1 - BLOCKER RING
Install second gear blocker ring (1). See Fig 14.

Fig 15: Second Gear Friction Ring
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1 - FRICTION RING

Install second gear friction ring (1). See Fig 15.

Fig 16: Proper Installation of Synchronizer Components

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1 - FRICTION CONE

2 - FRICTION RING

3 - BLOCKER RING

Install second gear friction cone (1). All parts should be flush. See Fig 16.

Fig 17: Proper Second Gear Installation
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1 - BUSHING

2 - BEARING

3 - SECOND GEAR
Install second gear (3). See Fig 17. Engage friction ring teeth with notches in gear. Components are properly installed when flush.

Fig 18: Third Gear Installation
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1 - INSTALLER 6448A

2 - THIRD GEAR
Using Installer 6448A (1), press third gear (2) until it bottoms. See Fig 18.

Fig 19: Fourth Gear Installation
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1 - INSTALLER 6448A

2 - FOURTH GEAR (COLLAR DOWN)
Using Installer 6448A (1), press fourth gear (collar down) (2) until it bottoms. See Fig 19.

Fig 20: Fifth Gear Installation
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1 - INSTALLER 6448A

2 - FIFTH GEAR (COLLAR UP)
Using Installer 6448A (1), press fifth gear (collar up) (2) until it bottoms. See Fig 20.