Output Shaft: Disassembly

Fig 1: Exploded View Of Output Shaft

CAUTION: When pressing off components, hold the shaft so that it does not fall.

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 secondary third gear.
  
  Fig 2: Measuring Output Shaft Clearances
Use an (A) arbor press, (B) Shaft Protector, and (C) Bearing Pulling Attachment to press off the (D) bearing (fourth gear end).

Fig 3: Pressing Off (D) Bearing (Fourth Gear End)
Use an (A) arbor press, (B) Shaft Protector, and (C) Bearing Pulling Attachment to press off the (D) fourth speed gear.

Fig 4: Press Off (D) Fourth Speed Gear
Remove the snap ring.

Fig 5: Removing Output Shaft Snap Ring
Use an (A) arbor press, (B) Shaft Protector, and (C) Bearing Pulling Attachment to press off the (D) third speed gear and (E) second gear.

Fig 6: Pressing Off (D) Third Speed Gear & (E) Second Gear

CAUTION: The synchronizer blocking rings are not interchangeable. Be sure to keep them in the order that they were removed.

Fig 7: Removing Synchronizer Blocking Ring

CAUTION: The synchronizer blocking rings are not interchangeable. Be sure to keep them in the order that they were removed.

NOTE: Inspect all the synchronizer components for wear and damage; refer to SYNCHRONIZERS .

Fig 9: Pressing Off (D) Synchronizer Hub, (E) Synchronizer Blocking Ring, & (F) First Gear

Use an (A) arbor press, (B) Shaft Protector, and (C) press blocks to press off the (D) synchronizer hub, (E) synchronizer blocking ring, and (F) first gear.
Use (A) Shaft Protector and (B) Bearing Pulling Attachment to press off the (C) bearing (first gear end).

Fig 10: Pressing Off (C) Bearing (First Gear End)
Use Dial Indicator/Magnetic Base to measure output shaft gear runout.
- Inspect the output shaft for worn or damaged gears.
- Inspect the output shaft for clogged oil passage.
  
  Fig 11: Using Dial Indicator/Magnetic Base To Measure Output Shaft Gear Runout

NOTE: Set the synchronizer ring squarely in the gear, then measure around the circumference.

Inspect the synchronizer blocking ring.
- Measure the clearance from the side of the gear.
- Inspect for smooth engagement with the gear.
- Inspect for worn or damaged teeth or tapered surface.
  
  Fig 12: Measuring Clearance From The Side Of The Gear
Inspect the synchronizer hub.
- Inspect for worn or damaged splines, synchronizer insert groove or end surface.
- Inspect for smooth hub sleeve movement when it is installed.
Measure the clearance between the first/second synchronizer hub and its shift fork.

Fig 13: Measuring Clearance Between First/Second Synchronizer Hub & Its Shift Fork