Output Shaft: Assembly

NOTE: Whenever a bearing has been removed, it must be replaced with a new one.

Fig 1: Pressing On Bearing (First Gear Side)

Use an arbor press, (A) Shaft Protector, (B) Bearing Cone Replace and (C) Axle Bearing/Seal Plate to press on the bearing (first gear side).

NOTE: When installing the synchronizer blocking ring, align the synchronizer blocking ring groove and synchronizer hub inserts.

Fig 2: Pressing On (D) First Gear, (E) Synchronizer Blocking Ring, & (F) Reverse Gear

Use an arbor press, (A) Shaft Protector, (B) Bearing Cone Replacer and (C) Axle Bearing/Seal Plate to press on the (D) first gear, (E) synchronizer blocking ring, and (F) reverse gear.
Install the snap ring.

Fig 3: Installing Output Shaft Snap Ring

NOTE: When installing the synchronizer blocking ring, align the synchronizer blocking ring groove and synchronizer hub inserts.

Fig 4: Pressing On (D) Synchronizer Blocking Ring, (E) Second Gear, & (F) Third Speed Gear

Use an arbor press, (A) Shaft Protector, (B) Bearing Cone Replacer, and (C) Axle Bearing/Seal Plate to press on the (D) synchronizer blocking ring, (E) second gear, and (F) third speed gear.
Install the snap ring.

Fig 5: Installing Output Shaft Snap Ring
Use an (A) arbor press, (B) Shaft Protector, (C) Bearing Cone Replace, and (D) Axle Bearing/Seal Plate to press on the (E) fourth speed gear.

Fig 6: Press On (E) Fourth Speed Gear
Use an (A) arbor press, (B) Shaft Protector, (C) Bearing Cone Replacer, and (D) Axle Bearing/Seal Plate to press on the (E) bearing (fourth gear side).

Fig 7: Pressing On (E) Bearing (Fourth Gear Side)

NOTE: If not within specifications, disassemble and reassemble the output shaft assembly.

Measure the output shaft clearances.
1. Measure the clearance between first gear and the differential drive gear.
2. Measure the clearance between second gear and third gear.
  
  Fig 8: Measuring Output Shaft Clearances