Output Shaft

Lubricate shaft, gears and bearings with recommended lubricant during assembly. Petroleum jelly can be used to hold parts in place. Check bearing surfaces of output shaft for nicks or scratches. Smooth surfaces with 320/400 grit emery cloth if necessary. Apply oil to emery cloth and shaft surface before polishing.

Inspect and replace any synchro ring if worn or damage. Immerse each synchro ring in lubricant before installation.

Lubricate and install reverse gear needle bearing on shaft (see Fig 1). Slide bearing up against shoulder on output shaft.

Fig 1: Reverse Gear Bearing
Install reverse gear over needle bearing (see Fig 2).

Fig 2: Reverse Gear
Install brass synchro ring on reverse gear (see Fig 3).

Fig 3: Reverse Gear Synchro Ring
Assemble fifth-reverse synchro hub, sleeve, struts, springs and detent balls, if not previously done.
CAUTION: One side of the hub has shoulders around the hub bore, this side of the hub faces the front of the shaft. One side of the sleeve is tapered the tapered side faces the front of the shaft.
Start fifth-reverse synchro assembly on output shaft splines by hand. Then seat synchro onto shaft with a press and Cup 6310-1 (see Fig 4).

Fig 4: Fifth-Reverse Synchro Assembly
Install new fifth-reverse hub snap ring (see Fig 5) and verify the snap ring is seated.
NOTE: Snap rings are available in thicknesses from 2.00 mm to 2.20 mm (0.078 to 0.086 in.). Install thickest snap ring that will fit in shaft groove.

Fig 5: Fifth-Reverse Synchro Hub Snap Ring
Install fifth gear synchro ring in synchro hub and sleeve (see Fig 6).

Fig 6: Fifth Gear Synchro Ring
Install fifth gear bearing, spreading bearing only enough to clear shoulder on output shaft (see Fig 7). Verify bearing is properly seated.

Fig 7: Fifth Gear Bearing
Install fifth gear on shaft and onto bearing (see Fig 8).

Fig 8: Fifth Gear & Bearing
Invert output shaft and set the shaft in Cup 6310-1 so that fifth gear is seated on the tool (see Fig 9).
Install first gear bearing on output shaft (see Fig 9). Verify bearing is seated on shaft shoulder and is properly joined.

Fig 9: First Gear Bearing
Install first gear on shaft and over bearing with bearing synchro cone facing up (see Fig 10).

Fig 10: First Gear
Install first gear synchro ring (see Fig 11).

Fig 11: First Gear Synchro Ring
Assemble 1-2 synchro hub sleeve, springs, struts and detent balls.
CAUTION: The 1-2 synchro hub and sleeve can be installed backwards. One side of the synchro sleeve is marked First Gear Side. Verify this side of the sleeve is facing first gear.
Start 1-2 synchro assembly on shaft by hand (see Fig 12). Verify synchro sleeve is properly positioned.

Fig 12: Starting 1-2 Synchro
Press 1-2 synchro onto output shaft using suitable size pipe tool and shop press (see Fig 13).
CAUTION: Align the synchro ring and sleeve as hub the is being pressed onto the shaft. The synchro ring can crack if not aligned.

Fig 13: Pressing 1-2 Synchro Onto Output Shaft
Install interm ring.
Install new 1-2 synchro hub snap ring (see Fig 14) and verify the snap ring is seated.
NOTE: Snap rings are available in thicknesses from 1.80 mm to 2.00 mm (0.070 to 0.078 in.). Install thickest snap ring that will fit in shaft groove.

Fig 14: 1-2 Synchro Hub Snap Ring
Install second gear synchro ring in 1-2 synchro hub and sleeve (see Fig 15). Verify synchro ring is properly seated.

Fig 15: Second Gear Synchro Ring
Install synchro friction cone and synchro cone in synchro ring.
Install second gear needle bearing on shaft (see Fig 16).

Fig 16: Second Gear Bearing
Install second gear onto shaft and bearing (see Fig 17). Verify second gear is fully seated on synchro components.

Fig 17: Second Gear
Install two-piece thrust washer (see Fig 18). Ensure washer halves are seated in shaft groove and that washer lugs are seated in shaft lug bores. Verify i.d. grooves and markings noted during removal are facing the correct direction.

Fig 18: Two-Piece Thrust Washer
Start retaining ring around two-piece thrust washer (see Fig 19). Ensure locating dimple is between the thrust washer halves.

Fig 19: Retaining Ring
Seat thrust washer retaining ring with plastic mallet (see Fig 20).

Fig 20: Thrust Washer Retaining Ring
Install third gear needle bearing on shaft (see Fig 21).

Fig 21: Third Gear Bearing
Install third gear on shaft and bearing (see Fig 22).

Fig 22: Third Gear
Install third speed synchro ring on third gear (see Fig 23).

Fig 23: Third Speed Synchro Ring
Assemble 3-4 synchro hub, sleeve, springs, struts and detent balls.
Start 3-4 synchro hub on output shaft splines by hand (see Fig 24).
CAUTION: The 3-4 synchro hub and sleeve can be installed backwards. One side of the sleeve has grooves in it. This side of sleeve faces the front of the shaft.

Fig 24: 3-4 Synchro Hub On Output Shaft
Press 3-4 synchro assembly onto output shaft with shop press and suitable size pipe tool (see Fig 25).
NOTE: Place the pipe on hub as close to output shaft as possible without contacting the shaft splines.

Fig 25: Pressing 3-4 Synchro On Output Shaft
Install 3-4 synchro hub snap ring (see Fig 26) and verify snap ring is seated.
NOTE: Snap rings are available in thicknesses from 2.00 mm to 2.30 mm (0.078 to 0.090 in.). Install thickest snap ring that will fit in shaft groove.

Fig 26: 3-4 Synchro Hub Snap Ring
Install output shaft bearing.
Secure output shaft as necessary. Install output shaft bearing snap ring, spreading it just enough to install it. Verify snap ring is seated in shaft groove (see Fig 27).

Fig 27: Output Shaft Bearing Snap Ring
Verify position of synchro sleeves before proceeding with assembly operations (see Fig 28). Grooved side of 3-4 sleeve should be facing forward. First gear side of 1-2 sleeve should be facing first gear. Tapered side of fifth-reverse sleeve should be facing forward.

Fig 28: Synchro Sleeve Locations