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Input Shaft: Assembly

Fig 1: 3rd Gear Caged Needle Bearing
GC0020166Courtesy of DAIMLERCHRYSLER CORP.
1 - INPUT SHAFT
2 - 3RD GEAR CAGED NEEDLE BEARING
  1. Place input shaft into shop press.
  2. Install 3rd gear caged needle bearing (2). See Fig 1.
    Fig 2: Press On 3rd Gear Synchronizer Hub
    GC0020167Courtesy of DAIMLERCHRYSLER CORP.
    1 - PRESS RAM
    2 - SLEEVE C-3717
    3 - BEARING SPLITTER
    4 - 3RD GEAR SYNCHRONIZER ASSEMBLY
  3. Install 3rd gear and 3-4 synchronizer (4) onto input shaft. Install Sleeve C-3717 (2) over input shaft and press on synchronizer hub and 3rd gear. The synchronizer hub has the letter U  stamped on the top face of the hub. This designates that the hub must be installed with the U  facing upward. See Fig 2
    Fig 3: Split Thrust Washer Separation Pin
    GC0020161Courtesy of DAIMLERCHRYSLER CORP.
    1 - SEPARATION PIN
    2 - INPUT SHAFT
    3 - PLIERS
  4. Install 3-4 synchronizer snap ring into slot on input shaft.
  5. Install blocking ring into 3-4 synchronizer. Install 4th gear caged needle bearing.
  6. Install 4th gear onto input shaft.
  7. Install 4-5 split thrust washer separation pin (1). See Fig 3.
    Fig 4: Split Thrust Washer Removal/Installation
    GC0020160Courtesy of DAIMLERCHRYSLER CORP.
    1 - INPUT SHAFT
    2 - SPLIT THRUST WASHER
  8. Install split thrust washer (2) onto input shaft (1). See Fig 4.
    Fig 5: Retaining Ring Installation
    GC0020168Courtesy of DAIMLERCHRYSLER CORP.
    1 - SPLIT THRUST WASHER RING
    2 - INPUT SHAFT
  9. Install split thrust washer retaining ring (1). See Fig 5.
    Fig 6: Caged Needle Bearing Removal/Installation
    GC0020158Courtesy of DAIMLERCHRYSLER CORP.
    1 - INPUT SHAFT
    2 - CAGED NEEDLE BEARING
  10. Install 5th gear caged needle bearing (2). See Fig 6.
    Fig 7: 5th Speed Gear Installation
    GC0020169Courtesy of DAIMLERCHRYSLER CORP.
    1 - PRESS RAM
    2 - SLEEVE C-3717
    3 - SYNCHRONIZER ASSEMBLY
    4 - BEARING SPLITTER
    5 - 5TH SPEED GEAR
  11. Using special Sleeve C-3717 (2), install 5th speed gear (5) and synchronizer (3). The 5th gear synchronizer hub has the letter S  stamped on the top face of the hub. This designates that the hub must be installed with the S  facing upward. See Fig 7.
    Fig 8: 5th Gear Synchronizer Snap Ring Removal/Installation
    GC0020156Courtesy of DAIMLERCHRYSLER CORP.
    1 - SNAP RING PLIERS
    2 - INPUT SHAFT
    3 - BEARING SPLITTER
    4 - SNAP RING
  12. Install 5th gear synchronizer snap ring (4). See Fig 8.
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