Output Shaft: Description: Disassembly

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

Fig 1: 4th/5th Gear Removal

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1 - TOOL 8918

2 - 5TH GEAR

3 - 4TH GEAR

4 - PLATE 8925-2 / 8925-4

5 - FIXTURE 8925-3

Install output shaft to fixture 8925-3.(5) Use split plate 8925-2 on diesel models, and 8925-4 (4) on turbo models.

Remove 4th (3) and 5th gears (2) simultaneously. Install protective sleeve 8918 (1) to output shaft and press 4th and 5th gears off of shaft. See Fig 1.

Fig 2: 3rd Gear Removal

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1 - TOOL 8918

2 - 3RD GEAR

3 - SPLIT PLATE 8925-1

4 - FIXTURE 8925-3

Install output shaft to fixture 8925-3 (2) using split plate 8925-1 (3). See Fig 2.

Remove 3rd gear (1). Install protective sleeve 8918 (1) to output shaft and press 3rd gear (2). See Fig 2off of shaft.

Fig 3: 1st Gear, Synchro, and Bushing Removal

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1 - TOOL 8918

2 - BUSHING

3 - 1-2 SYNCHRONIZER

4 - 1ST GEAR

5 - SPLIT PLATE 8925-2 (INVERTED)

Remove second gear from output shaft.
Remove second gear needle bearing.
Install output shaft to fixture 8925-3 using split plate 8925-2 (5). See Fig 3(inverted).

Install protective sleeve 8918 (1) to output shaft and simultaneously press off 2nd gear bushing, 1-2 synchronizer (3), and 1st gear (4). See Fig 3.

Fig 4: Output Shaft Assembly

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1 - OUTPUT SHAFT ASSEMBLY

2 - 5TH GEAR

3 - 4TH GEAR

4 - 3RD GEAR

5 - 2ND GEAR NEEDLE BEARING

6 - BUSHING

7 - 2ND GEAR

8 - FRICTION RING

9 - CONE

10 - BLOCKER RING

11 - 1-2 SYNCHRONIZER

12 - 1ST GEAR NEEDLE BEARING (2)

13 - 1ST GEAR

14 - OUTPUT SHAFT

Remove 1st gear needle bearings (12) from shaft. Inspect thrust washer (fixed to shaft). See Fig 4.