Output Shaft

NOTE: The synchronizer hubs and sleeves are different and must not be intermixed. Remove each synchronizer unit as an assembly to avoid intermixing parts. Reference mark or tag each synchro hub and sleeve for correct assembly.

Remove snap ring that secures 3-4 synchro hub on output shaft.
Remove 3-4 synchro assembly, third gear synchro ring and third gear with shop press and Bearing Splitter 1130. Position splitter between second and third gears.
Remove third gear needle bearing (see Fig 1).

Fig 1: Third Gear Needle Bearing
Remove retaining ring that secures two-piece thrust washer on shaft (see Fig 2). Use a small pry tool to remove retaining ring.

Fig 2: Thrust Washer Retaining Ring
Remove two-piece thrust washer (see Fig 3). Note position of washer locating lugs in shaft notches for installation reference.

Fig 3: Two-Piece Thrust Washer
Remove second gear and needle bearing Fig 4).

Fig 4: Second Gear & Needle Bearing
Remove second gear synchro ring, synchro friction cone and synchro cone (see Fig 5).

Fig 5: Second Gear Synchro Ring And Cones
Remove interm ring.
Remove 1-2 synchro hub snap ring.
Remove 1-2 synchro hub and sleeve and first gear from output shaft with press and Bearing Splitter 1130 (see Fig 6). Position splitter between first and reverse gears.

Fig 6: Hub Sleeve And 1-2 Synchro
Remove first gear needle bearing (see Fig 7).

Fig 7: First Gear Needle Bearing
Remove output shaft bearing snap ring (see Fig 8).

Fig 8: Output Shaft Bearing Snap Ring
On 2-wheel drive models, remove output shaft bearing.
Remove fifth gear (see Fig 9).

Fig 9: Fifth Gear & Synchro Ring
Remove fifth gear needle bearing. Spread bearing apart just enough to clear shoulder on output shaft (see Fig 10).

Fig 10: Fifth Gear Needle Bearing
Remove fifth-reverse synchro hub snap ring (see Fig 11).

Fig 11: Fifth-Reverse Synchro Hub Snap Ring
Remove fifth-reverse synchro hub and sleeve with a press (see Fig 12).

Fig 12: Fifth-Reverse Synchro Hub And Sleeve
Remove reverse gear and needle bearing (see Fig 13).

Fig 13: Reverse Gear And Needle Bearing